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REMOTE PROCESS INTERFACE MANUAL

1. il When the RPI is used marshalling is not necessary since this procedure is followed by addres sing the RPI internal bus Note p p S EELL 2 gt ull ie 53 N ET e oj fll a fE TS S T e oO E s If Fa NE E S H S 00 p am 00 NE E x fea x z O r O ER e E I o IN T fee gt C aH BBE e c Bell a fk s ET e GO EE z E N e aTe ie SO fs E o ire tt O o J e oj H Q N g o H 3 Te Hell e oO ei a as O c E e oj EET O l e 7 3 Labeling ret ey Power feed module E saul Internal bus connection NE ae ee S a e gt Be ee DIS GJS F GJS o GS GS GIS GG G GJS S GJS G GG o S S S O G9 8 oS oss SS SI S S SHS S ses soslses S SJC SHS Sje Ss 8 FB FB FB FB FB FB FB FB FB FB 2 olja aoje ai DS S S SEES ESN ESEN EE SESE ESE SSE S ejO S Sje o SO G ee G Soe G G S G Se S oe oe eoe e A Lars FB Function module Gateway NE 4 Ww
2. Reading Binary Input Data without Status 0 0 0 cece ceccc ee eeeeceece ee eecee cece ae eaesaeeeeaeeaegeeaeseeaeeseaaeeeeaeeeeages Reading binary input data with status Writing Reading Binary Output Data without Status 0 0 0 0 ce cec ce eseeceeae ea eeecesneeeeeaeseeseeeaesaeeeeeaaeeeseneaa ees Writing Reading Binary Output Data with Status 2 0 0 cccccecseceeneececeeeeeeeeseeaeaneeeaeseeeseeeseeaeeeeaeaneeeanaaes Reading Analogue Input Data without Status 2 0 0 0 cceeceeeeneeeeeeeceeeeeeeeeeeeeaeeaeeeaneeeeseaeseeaneseaeeeseeseseees Reading Analogue Input Data with Status Writing Reading Analogue Output Data without Status cc cccceceeeeeee ae eeenceeeeeeaeaeeeeeeeeeeaeeeeeeeeasanes Writing Reading Analogue Output Data With Status ccc cceeseececeseeeeeeeeeaeeneeeaeseeeseaeseeaeeeaeaneeeanaass Special case Holding Register cssricereisendansevaiacinarvncsutesnereasuandunsiveeuasedssivedaead sae cnsdenuvesvdeawaenscceninncddexewenevbdews Configuring an RPI System via the Host cccccccsececeseeeeeeseaeeeeeeaeeaeeeceeeseeeeaeeneeeeeaueeeeeaeeeeeeaueaeseeeea sess DANOS eee E oo saaaasstincesninseeeacesscn see rscamseacupednaciieaneaoaudeorseaseatetysaunecnseoasaeaecamn aadeetencaaddceeesncddeeeess Summary of Tables Gateways for the MODBUS Plus Gateways KSD2 GW MPL and KSD2 GW MPL 485 DEVICES COMME CHORD MER Modbus FIUS s 6 8 icc ar e
3. IS GJS GJS S GIS GIS GIS 8 Gos IS GS Sje 8 s ssalescless ses SS A g4 94 94 Gs Gs Gs 94 94 94 94 94 84 94 84 Gs 94 94 94 84 84 94 H ea Figure 4 16 Example of the arrangement of an RPI system The internal bus connection shown in this figure is achieved by connecting terminals 12 13 and 15 of the power supply modules Terminals 13 and 15 make a connection to the Power Rail internal transmission line Terminal 12 corresponds to the earth potential of the supply line This is necessary since then the internal redundancy thereby ensures that the signal from the voltage difference of a transmission line terminal 13 or 15 and the earth potential terminal 12 can be won back When adopting a horizontal assembly it can be useful when an assembly string is identical with a segment Every power supply module and hence every device on the related segment is protected by a fuse Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 61 4 11 4 11 1 4 11 2 62 Remote Process Interface Planning of the RPI System Installation General Information on Device Connection
4. aia lt 001 000 gt KSD2 GW MPL Parameter joj x 15 x Communication Password display Intemal communication Display Operation mode Master gateway device address 1 T Panel locked Internal cpcletime f ms ys pana MPL Parameter Password 1 JPEFU Password aktive Adresse fiz G r Password 2 PEFU Parametization mtelace Address fo Help Close Figure 6 6 Parameterizing the Modbus Plus Gateway The Password Panel tab enables you to lock the operating unit and to activate the passwords by checking the respective boxes 6 3 2 3 PROFIBUS DP and DP V1 The tab for the gateway parameters contains the tabs Communication and Password Panel Two pa rameters have to be set for the communication of the gateway e Address on the PROFIBUS 0 127 e Address of the parameterization interface 0 127 as set on the gateway The section Internal Communication indicates theOperating Mode and the Internal Cycle Time However they cannot be changed lt 001 000 gt KSD2 GW PRO_485 Parameter o xj N lt 001 00 loj xj Communication Password display Communication Password display intemal communication maa aii Display Upershonimode Master gateway device addiess 1 E Panel locked intemal cycletime 25 ms Z TERE p PROFIBUS DP parameter Password 1 PEFU Password aktive Address 5 Password 2 PEFU z Parametrization interface
5. ksp2cisex abroas 6e soyes p40 kozase ann 7 J zwe S O Itis not possible to combine INT and FLOAT or with status and without status in a transmis il sion This is a PROFIBUS constraint H o1 O Further restrictions are a maximum of 64 DP slave modules per RPI system and a maximum of il 244 bytes for the identifier of I O data This corresponds to the sum of all bytes in the input out put address column The data of a maximum of 48 analogue modules with status and Floating Point format can be transmitted using 244 bytes Note Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 121 Remote Process Interface 7 2 9 3 Format of the Input and Output Data As described in the previous section the module identifier specifies the data type and format and whether status information is to be transmitted The format of the input and output data for the individual module ty pes is described in this section O It should be noted that input and output data each have their own data area This means that for output modules where status information is to be transmitted in addition to the user data the status information is in the input data area and is not transmitted with the user data as is the No
6. E D Teach in of an existing configuration Ifthe RPI devices already have addresses on the internal bus the structure can be uploaded to the gateway by means of the Teach in function Existing parameters are likewise uploaded from the RPI devices This function helps you to commission RPI quickly or to teach in hardware changes However you must ascer tain that you keep track of these changes in your software human machine interface Alternatively the values for the configuration of the RPI system can be set by means of a software human machine interface or via PROFIBUS DP A detailed description of the configuration via the gateway can be obtained from Chapter 5 4 2 Operating the Gateways Type KSD2 GW or Chapter 5 4 3 Operating the Gateways of Type KSD2 GW2 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 71 Remote Process Interface Configuring and Commissioning the RPI System LC Display Button ESC Button Up Button OK Button Down 5 4 1 Construction of the Gateways and LEDs on the Front Panel The four LEDs on the front panel indicate the current status of the device as well as hardware and commu nication errors The four LEDs are identical for the gateways KSD2 GW and
7. 0 an error message is generated If the address of the new device is identical to that of another device then its function is termi nated and a second error message ensues In this case the correct address should be immedi ately allocated to the new device as described in Chapter 7 Replacement in the event of the simultaneous failure of a number of devices If the failed devices are all of different types they are simply replaced as described under Replacement in the case of failure of a single device The replacement devices are identified by the gateway The correct addresses for the internal bus are assigned automatically The parameters are loaded into the devices The system informs the control system that full serviceability has been regained in that the existing error mes sages are withdrawn If more than one device of a type has failed the defective devices are removed from the rail The replace ment devices are set to the address 0 at the factory They are snapped onto the rail one after the other in ascending order of address for the internal bus The gateway automatically assigns the lowest address of all the failed devices on the internal bus to each new device Then the parameters are automatically loaded into the new device The next replacement device can then be snapped onto the rail O When using this method no addresses parameters or measurement ranges must be set when il servicing Straightforward rep
8. 12 1 12 1 1 12 1 2 12 1 3 12 1 3 1 12 2 12 2 1 12 2 2 12 2 3 12 2 4 12 3 12 3 1 12 3 2 12 3 2 1 12 3 2 2 12 3 2 3 12 3 2 4 12 3 2 5 12 3 2 6 12 3 2 7 12 3 3 12 3 3 1 12 3 3 2 12 3 3 3 12 3 3 4 12 3 4 12 3 4 1 12 3 4 2 12 3 4 3 12 3 4 4 12 3 4 5 12 3 4 6 10 Redundant Internal BUS System ssssssssnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nnnm nunen nnmnnn nennu nenna nnna nnmnnn nnna Redundant Extemal BUS SYSTEM csssccssossccseicescecseneccenececetaenweciercadtserwocanceasmeredicasbevensescesucndenss Wseanatbeciens Construction of a Redundant External Bus System with Gateways c cccsesseeeeeceeeeeeeeeeeeeeeeeees RPI SYSTEM ERROR MESSAGES icccccccccccccneccencnccnccnccccceceeensnennenseneeseucesennsensnens Error Messages on the Display of the KSD2 GW Gateway 0cccccsssceseeseeeeeneeeeeeeeeeeaeeoeanensesaeeees Error Messages on the Display of the KSD2 GW2 Gateway cccccsseceeesecceseeeeeeneeeseeeaeeeeaneneaeanes Error Messages on the Gateways Via LED cccceceeeseeeeeeeeeeeeeeeeeneeeeeceeeeeseseeaesnseeseseaeeesaeaeansneneeees Error Messages on the RPI Devices via LED ui ccccecesecssseceseseeesenseeeseeenscesneneeasecesaeesaeeonsaeaneneesnsenaees RPI System Manual Table of contents 190 190 191 N Ue 192 192 193 196 K SK1 THE MAN MACHINE INTERFACE FOR THE CONFIGURATION PARAMETERISING SIMULATING TESTING AND MONITORING THE RPI K SK1
9. Teach In Service Menu 0 cccccseeeeeeceeeeeececeeecseaueeeeeeeseeessneeeessaneeeeens 86 Assignment of Device Addresses AdrAssign Service Menu ccccecceeeeeeeeeeeeeeeeeeeeeeeeeeaeaaeeeeeeesaaaaeeeeeessaaaees 86 Activation of the Redundancy RedMode Service Menu ccccseeeeeeceeeeeeeeeeeeeeceeceececeueeeeeeseueeeesauaueeesseseenens 87 SETTING THE ADDRESS OF THE RS 232 RS 485 SERVICE INTERFACE PARADR SERVICE MENU 1 ceccenesensecnnsenes 87 SETTING THE TRANSFER RATE FOR THE RS 232 RS 485 SERVICE INTERFACE PARBAUD SERVICE MENU 0 00 87 SETTING THE GATEWAY ADDRESS ON THE EXTERNAL BUS HSTADR SERVICE MENU ssceeceenccennsnensenesennscnnsennsenes 88 SETTING THE HART TRANSMISSION HART SERVICE MENU eccesccenccnnccnscennccnnnsnensenseennsnensenssenssnanseussensseenseunsenes 88 Resetting Internal Communication ReslntCom Service Menu cccccceccseseeeeceeeeeeeeeeeeeeeeeeeeeesaaeeeessaneeeeeas 88 Switching Back from Redundant Operation SetActiveMode Service Menu cccccseeeeceeeeeeeeeeeeeeeeeeeeeeeseaes 88 Information on Hardware and Software Versions Info Service Menu cccceccsecsceceeeeeeeeeeeceeeeeeeeeeeeeaneeeees 88 Verification of Device Addresses 89 Checking the Device Address on the RPI Internal Bus 89 CHECKING BY MEANS OF KSD2 GW GATEWAY sicsicacecucesssessedeescese detects Naaa REENA E AAA EEEE EERE 89 Checking
10. 1 2 4 Kot 4 8 Kbit Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com T7 Remote Process Interface Configuring and Commissioning the RPI System 5 4 2 8 Setting the MODBUS Parameters On selecting the operating mode PARAM EXT only available on MODBUS gateway the current setting is shown in the display A different setting can be selected using the 48 and Y pushbuttons and accepted by depressing the mode pushbutton for longer than 3 s The following settings are available Setting Display indication No parity bit 1 stop bit 00 5 4 2 9 Teaching in Existing Configurations of the RPI Devices The current configuration of all connected RPI devices is uploaded to the gateway using the Teach in function Likewise existing parameter data of the devices is uploaded to the gateway This function is helpful in starting up the RPI rapidly or in teaching in hardware changes rapidly However you must ascertain that you keep track of these changes in your software human machine interface Depress the mode button for longer than 3 seconds All new settings of the RPI devices are now stored in the gateway O Bear in mind that you can use the human machine interface to keep track of the set up of your project Note j l This
11. Date of issue 05 27 03 Date of issue 05 27 03 Binary input data with status 1 4 channel modules MSB 1 Byte LSB STATUS CH1 7 Bit D1 MSB 3 Byte LSB STATUS CH3 7 Bit D1 MSB 5 Byte LSB STATUS CH1 7 Bit D2 Binary output data with status Remote Process Interface Module types n x 2DI_S nx4DI_S MSB 2 Byte LSB STATUS CH2 7 Bit D1 MSB 4 Byte LSB STATUS CH4 7 Bit D1 etc In the case of output data with status information the DP master sends the output data to the DP slave and receives the status data as input data in a reply telegram i e the output data is in the output data area and the status data is in the input data area of the module Output data area 1 channel modules MSB LSB ojojo o ns 1111 1 1 NSL ANANN D4 D3 D2 D1 2 channel modules MSB LSB BE ME AEA E E ASS 2 1 21 11 2 1 2 1 Input data area 1 2 channel modules MSB 1 Byte LSB STATUS CH1 7 Bit 0 D1 MSB 3 Byte LSB STATUS CH1 7 Bit D2 Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 123 Module types n x 1DO_S Module types n x 2DO_S Module types n x 1DO_S nx2DO _S MSB 2 Byte LSB STATUS CH2 7 Bit 0 D1 etc Copyright Pepperl Fuchs Printed in Germany 124 Data type signed integer 1 chan
12. Gateway There are two principal ways of checking the address which is held by a particular RPI device 1 By selecting the device in the Monitor menu of the gateway On the RPI device itself the green PWR LED flashes 2 By briefly depressing the ADR button less than 3 s on the device The gateway should be in the Run or in the Monitor menu The gateway display shows the address of the device and the device type Now the gateway is in the Monitor menu and should be reset to the normal mode Run by means of the Esc button On the device itself the green PWR LED flashes 5 5 2 Assignment of the Device Address for the Internal Bus The device addresses of the RPI internal bus are organised as follows Address Device 0 Neutral address of an RPI device the setting on delivery Active RPI gateway Redundant RPI gateway 3 127 RPI device 5 5 2 1 Address Assignment by Means of KSD2 GW Gateway e Select the operating mode b ADR INT set internal address with the Mode button on the gateway The lowest possible free device address is shown on the display e The device address can be changed using the Up and Down buttons Occupied and prohibited addresses are not displayed e After that depress the ADR pushbutton on the front panel of the device that is to be addressed for longer than 3 s e The displayed address is allocated to the device This is indicated by the green LED PWR flashing brief
13. Operation of the equipment under power and the connection to the power supply must only be AN carried out by appropriately trained personnel Attention Prior to connecting the RPI system ascertain that the power supply voltage is 24 V DC in accor dance with the RPI module data sheet When installing and operating devices with intrinsically safe circuits the certificates of confor mity and the relevant assembly and installation instructions DIN EN 50020 DIN VDE 0165 should be observed The electrical connection of the cables of RPI system devices is made by means of self opening screw ter minals in the removable terminal blocks max core cross section 1 x 2 5 mm Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Planning of the RPI System Connect the wiring as described in the connection diagram and the terminal allocation list for the individual devices The supply voltage is only connected to the power feed modules The external bus system is connected to the gateway An available service level is connected to the service interface of the gateway In the case of HART communication when using a HART multiplexer the latter must be connected ac cordingly
14. 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 43 4 4 4 5 4 5 1 44 Remote Process Interface Planning of the RPI System Calculating the RPI Cycle Time The internal RPI bus has a constant transfer rate of 250 kbit s The maximum number of RPI bus stations is 125 devices or 500 channels The gateway calculates the current cycle time depending on the stored configuration and communicates to every slave when cycle time it must answer The cycle time is calcu lated in such a way that low priority signals acyclic services can be transferred The cycle time for an RPI system is calculated from the following formula T UPDATE 53 Nmodules 38 Nanalogue i INbinary 53 Noutput bit 1 2 25 ms tbus 250 kbit s Nmodules Number of devices Nanalogue Number of analogue channels Nbinary Number of binary modules NoutputNumber of output modules binary and analogue The cycle time is set to the lower integral multiple of 5 ms Exemplary calculation an RPI system contains the following modules 10 KSD2 TI Ex 20 KSD2 Cl S Ex 10 KSD2 BO Ex2 45 KSD2 Bl Ex4 Thus the following parameters are obtained Nmodules Number of modules85 modules NanalogueNumber of analogue channels30 channels Nbinary Number of binary modules55 modules NoutputNumber of output modules binary and analogue 10 modules The cycle time is 55 ms O If the cycle time calculated for the RPI system is too long for y
15. 8 5 2 8 5 3 8 5 3 1 8 5 3 2 8 6 8 7 8 8 10 10 1 10 2 10 3 10 3 1 10 3 2 RPI System Manual Table of contents MONITORING SIMULATING MEASURED VALUES AND ERROR HANDLING RPFN OPERATION esecercevertccssenevsceuesureeentncuadentiensyavenss dunsavaceaes AER DETE EAEE eaa Displaying Measured Values snnsnsnnnnnnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnnn nnn nunn nnn nnnnnnn nunnu nn nnmn nanum nn nannan nennen mnnn ma na Displaying Erends a cerssecciad cred ie tt ase na aeaa aa E aE EE SiINUAHON sesa a E E Simulation of Input Signals 0 0 cc ccececeaseceaeeeceeeneeeeceaeeeeseeeeeeeeeeeeseeeeeeeeeeaeseeeeseeaeeseeeenaeeeeaeansaeaneeeeeeeeseeatas MUA OF OU UE NAS senere aa E N E O E Servicing and Diagnostic System n Via LEDs LCD and Pushbuttons on the Devices Via PC and PACTwareTM or RPI Human Machine Interface Error Handling Error Detection within the RPI ie E E 178 pees 178 sites 179 Error detection from the control system engineering CONSOLE cccececeeeececeeseceeneeeeceaeeeeaneeeeeaneeeaneneess Fault elimination within the RPI System cccccceceececece cece en eeeeeeaeeeeaeeeeeeaeeeeauaeaeaueaeeaeseeenaneeeanageesneeeees pets 179 oe 179 Error Detection Using the LEDs on the Devices ec eceeceeseeeeeneeneeeeeneueeeeeeausaeseseeaaeseesaneeeeasaaaaseseeanereenaneeeeags Error Detection Using the LC Display on the Gateway cccccccccsseeeeeeeeeeeeeceeceeeeseaaeeeees
16. Connection of the intrinsically safe and non intrinsically safe circuits is undertaken with due AN consideration of all locally applicable regulations directives and standards governing the hazar dous area Attention The installation and operation of devices with intrinsically safe circuits must be undertaken with due regard for the certificates of conformity and the applicable regula tions relating to construction and installation DIN EN 50020 DIN VDE 0165 The connection of a module on the Ex side is made on the removable blue terminal block via self opening screw terminals max core cross section 1 x 2 5 mm for rigid cable or 2 x 1 5 mm for flexible cable with plastic wire end ferrule The connection of a module on the non Ex side is made on the removable green terminal block via self opening screw terminals max core cross section 1 x 2 5 mm for rigid cable or 2 x 1 5 mm for flexible cable with plastic wire end ferrule It should be noted that appropriate plug connectors are available on the market which can be used to re place the screw terminals These plug connectors are fitted by crimping onto the wiring O il On connecting the supply voltage to the power supply module all RPI devices mounted on the y Power Rail are immediately supplied with power ote EMC Screening and Earthing The screening of cables provides protection against electromagnetic interference The screening of the bus line must be undertaken with
17. Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface In the signed integer format 3 registers have to be read The data is constructed as follows Register address 2 Register address 1 Register address Channel 3 Channel 2 Channel 1 6 registers have to be read in the floating point format These are constructed as follows Channel 1 Register address 1 Register address Channel 2 Register addresst3 Register address 2 Channel 3 Register addresst5 Register address 4 Data byte 4 Data byte 3 Data byte 2 Data byte 1 Data for unoccupied channels is set to 0 7 3 10 Reading Analogue Input Data with Status The status information occupies one register per channel of which 7 bits are used for the analogue data The structure of the status register is as follows ofo o0 o o 0 0 0 ew at Dal Bit O of the low byte Dat is always set to 0 Bits GW1 and GW2 are reserved for limit value monitoring CD1 to CD3 code the error that has occurred Q1 and Q2 provide information on signal quality The messages shown in the table below are generated instantaneously Good Seas a SC E a SSS Good noeror To fo fo 0 Measurement range exceeded fallen sen Simutea measured 1 0 4 0 1 0 Reseved SSS lt SSSSC SSC icT iT 1 iT Of OC 1 O Congwaionerr S ct 1 0 o RPldeviceerror o Field device eror iY No communication last g
18. Devices _ _ F3 Monitor F4 Disgrostic __ F5 Data __ F6 Next 6504576 Resources 75 LEER PRJ E Project tree L Com 1 COM Port RPI 12 3 2 1 TERMULGAN List of possibilities Show details 5 elect a device device and choose a function COM g The K SK 1 software contains some Windows specific elements close box etc Please refer to the Win dows manual for help on their function and use The project manager The window inside is called project manager It displays the current project tree and let s you select devices for monitoring diagnosis or simulation It provides a title bar four structure level buttons scroll bars if necessary anda show details check box The icon of the selected item is displayed in yellow 12 3 2 2 The menu bar The menu bar gives you full control of the program You can start any action you like to perform from the menu bar by selecting the right menu items The content of the menu bar and the availability of menu items may change depending on the active window below Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 199 12 3 2 3 12 3 2 4 12 3 2 5 12 3 2 6 12 3 2 7 200 Remote Process Interface K SK1 The short cut buttons These buttons are short cuts t
19. Lower 200 0 c Upper 850 0 T Dutput Mal function Maximum 7 Value output status Online monitoring of random process variables 007p KSD2 TI EX Monitor 10 x Kanal PLT Stelle l l l l 00 125 0 250 0 3750 500 0 7 Daten zyklisch aktualisieren Help Close Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Planning of the RPI System Trend display Trends of random process variables are displayed lt 007 gt KSD2 TI EX Trend Display CI Channel 1 short circuit O Channel 1 lead breakage O Channel 1 Low Singal war O Channel 1 High Signal War OI Channel 1 Low Signal Alar ee ee signal L Channel 1 High Signal Alar O Channel 1 Signal over Wes O Channel 1 Signal under Me q y se 100 ooo mo 0 20 oso Too 110 4 Sen Bee IE ae ow 050 R Cyche refresh data re Help Close Simulation Simulation of all measured variables and diagnostic data lt 8 005p KSD2 CO S EX H Simulation Activate simulation Process value Help Close Diagnosis All diagnostic information is accessible via PACTware lt 007 gt KSD2 TI EX State O x Error Ino enos CTIVE Config ASD2 TI EX PROJ Config KSD2 TIEX Device
20. Space for connection cable e i field cable f r Ex and i t Ol non Ex signals m oo i 6 Spacer bolts for mounting t in control cabinets i t t 7 Mounting plate i m 8 Terminal gt EH en 9 Power Rail RPL madules t iF a h KF profile wilh Power Rail i t 1 _ t Base Figure 3 6 Possible arrangement of an RPI system in a control cabinet Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 4 4 1 Planning of the RPI System Remote Process Interface Planning of the RPI System PLANNING COMMISSIONING CONFIGURATION AND PARAMETER ASSIGNMENT O Pepperl Fuchs offers planning and mounting of complete control cabinet systems for the il assembly of RPI systems Local Pepperl Fuchs sales offices will be pleased to advise on alternative installations and the Note Planning Basics and Procedure most suitable control cabinet layout for a given application Figure 4 1 shows how to proceed when planning an RPI system The individual steps are explained in the following chapters whose numbers are given in the diagram below Process technology application determination of number and type of the loops see cha
21. The value of the status counter is stored in this byte The status counter is an 8 bit counter that is incremen ted every time a change is made to the status information Byte 12 Param counter The value of the parameter counter is stored in this byte The parameter counter is an 8 bit counter that is incremented every time a change is made to the parameter assignment whether via the gateway or via an RPI module O When module 0 access is activated see Chapter 7 2 2 additional information is inserted after il byte 12 Param Counter Note Module 0 access has no significance for normal operation More information about module 0 access is available on request Module specific diagnostic information The start of the module specific diagnosis data is identified by a header byte Header byte Module diagnostics header MSB LSB no 7 6 5 4 3 2 1 0 Block length header byte incl in byte Fixed on 01 Module specific diagnosis information with the block lengths specified in the header byte follow the header byte Each bit in these diagnosis bytes represents a DP module If a bit is set diagnostic information is available for that module Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date
22. These error codes can be read from register table 4 NIN NINI a ay CO CO NI OD O1 AJ O Register address RPI address 4355 If the status of the RPI system is changed e g through a change in the configuration device error or chan nel error a counter is incremented This 8 bit counter can be read from register table 4 Register address 4480 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 16 meaty 7 3 16 162 Remote Process Interface Summary of Tables Binary inputs without status Reg Tab Register address Channel based max 8 channels 8 RPI address channel number 1 1 device per register 4 devices per register Poowcesperegeter ee 2 devices per register Breger por gewo 2 registers per device reper per dene 4 registers per device Binary inputs with status Reg Tab Register address Device based max 4 channels 2 RPI address 3 3587 2 registers per device Device based max 8 channels 4 RPI address 3 3084 4 registers per device Binary outputs without status Reg Tab Register address Channel based max 8 channels 8 RPI address channel number 1 2 devices per register 4 devices per register Binary outputs with status Reg Tab Register
23. com T e ee o SO 2 GvF PRIO in lt 003 gt KSD2 C1 5 4 H HART protocol Master ane Master 5 arr E Ga EF gt KSD2 B0 ExX2 2 ey oa lt ourp KSD2 TIEX retties Figure 6 4 Parameterizing the HART protocol driver Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 97 6 3 1 3 6 3 2 6 3 2 1 6 3 2 2 98 Remote Process Interface Parameter Assignment Device Type Managers for Non RPI Devices DTM for field devices or interface modules not relating to the RPI system can likewise be embedded into the project tree To do this one needs suitable communication drivers These must conform to the FDT standard For more detailed information please refer to the handbook of the relevant device Gateway Parameters MODBUS RTU The tab for the gateway parameters contains thecommunication and the Password Panel tab The fol lowing four parameters must be set for the communication of the gateway e Address on the MODBUS 0 127 e Baud rate 1 200 57 600 bit s e Parity stop bit no 1 stop bit odd 1 stop bit even 1 stop bit no 2 stop bits e Address of the parameterization interface 0 127 as set on the gateway The section Internal Communication indicates the Operating Mode andthe Internal Cycle Time However
24. is 1 5 bar The measured value is transferred via the external bus with a factor of 100 i e for instance at 2 5 bar a value of 250 is transferred By means of the settings As Input Minimum Maximumor Hold Last Value the signal transferred to the control system in the error case is determined according to the application For the setting As Input a value should be entered in the box on the right hand side Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 6 3 8 Temperature Converter Remote Process Interface Parameter Assignment The Parameter tab contains both device specific and channel specific parameters Ohm Linear ry Pt 100 Ni 100 Thermoelement Typ K Thermoelement Typ T Thermoelement Typ E Thermoelement Typ J Thermoelement Typ N Thermoelement Typ A Figure 6 14 Parameterizing KSD2 TI Device Address Tag Data Tag Name Sensor Sensor Type Connection Method Unit Linearization Table Lead breakage detection Short circuit detection Limit Values Warning limits active Alarm limits active Measuring Range Start End Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 e USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com lt 007 gt KSD2 TI EX Parameter __ zinj xj T Device address a
25. most important function is to edit the current project displayed in the project manager This section describes only the basic set up The normal operation of RPI including monitoring diagnosis and simulation is des cribed later 12 3 3 1 Overview This section is only an overview to give you an impression of the standard workflow The following sections will describe each of the steps more detailed To create a new project do the following 1 Create a new project 2 Save the project under the name you want the project to be refered to 3 Edit the project in edit mode 4 Save all the changes to that project When finished you might want to configure your gateway accordingly To do so 1 Make sure that your gateway is powered and correctly connected to your PC 2 Choose Project download By now you have a correct set up in your PC and your gateway You can build your cabinet right now by adding device by device to the cabinet They will be configured according to that project laid down in the gateway 12 3 3 2 Creating anew project Select Project New from the menu The project manager is reset and the project name is set to noname prj See Editing a project for more information about changing the project information Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091
26. nj int External bus Button Up Button Down Mode button Rotary switch RS 232 termination resistor 3 5 mm Jack bush oe for Modbus Removable terminals green Figure 7 2 KSD2 GW MOD gateway Features of KSD2 GW 2 MOD KSD GW MOD 485 gateways The gateways connect the RPI internal CAN bus to the external Modbus RTU The gateway thus assumes the master function for the internal bus The gateway has the function of a slave device on the external Mod bus Toincrease system availability the gateway and external bus can be implemented in a redundant con figuration Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 135 7 3 1 136 Remote Process Interface Device Connection The electrical connection of the KSD2 GW MOD Modbus gateway by means of a cable merely involves establishing the Modbus connection The Modbus interface is an RS 485 on which up to 32 stations can be operated The service interface can be either an RS 232 KSD2 GW MOD or an RS 485 interface KSD2 GW MOD 485 it is used to configure and parameterize the RPI system with the RPI human machine interface To do this the PC is connected to the gateway via the service interface If the RS 232 interface is used connection to the PC can be made via the K ADP2 adapter A jack socke
27. they cannot be changed a lt 001 000 gt KSD2 GW MOD Parameter ioj xj iojxj Communication Password display M Intemal communication m Display Operation mode Master gateway di dress 1 f Panel locked Internal cycletime fe ms Passwords MODBUS Parameter Password 1 PEU Password aktive Address 126 Baudrate fi9200 Bits Password 2 PEFU Parity 1 stoobi stopbit none stopbit m Parametnzation interface Address 0 ened 0 aN Help Close Figure 6 5 Parameterizing the Modbus RTU gateway The Password Panel tab enables you to lock the operating unit and to activate the passwords by checking the respective boxes MODBUS Plus The tab for the gateway parameters contains the tabs Communication and Password Panel Two pa rameters have to be set for the communication of the gateway e Address on the MODBUS 0 127 e Address of the parameterization interface 0 127 as set on the gateway The sectionInternal Communication indicates the Operating Mode andthe Internal Cycle Time However they cannot be changed Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Parameter Assignment
28. x PKs02 Tr 32 yes yes yes yes x x x x rKsp2co 32 yes ves x x x x Table 4 2 Miscellaneous functions of the RPI devices annn Onan HH x lt x lt x lt x lt Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Planning of the RPI System 4 1 6 Selecting the RPI Devices Now that you have determined the functions and miscellaneous functions as described above you can sel ect the individual RPI devices according to the following procedure 1 Device type Which sensor actuator or field device must the RPI device support 2 ls the sensor actuator or field device located in a hazardous area Not all of the devices in the RPI system are certified for application in the AN hazardous area When selecting appropriately certified devices for the hazardous area attention must be paid to Atenton ihe permitted connection values the class of ignition protection and the category 3 Ils a HART or a SMART protocol transferred see Chapter 4 2 Planning the Transmission of HART Protocols 4 Which requirements of the control system must the RPI modules meet see Chapter 7 2 8 GSD Files 5 Is it possible to use multi channel devices The PAC Tware software enables the devices to be parameterized channel by channel and thus to connect a number of field devices of the same type with different param
29. 2 channels are packed binary output data with status information RPI device type KSD2 BO Ex2 In addition to the modules shown above other modules that perform special functions are defined These are Empty modules O Empty modules allow place holders to be included in the DP master configuration for modules that are not yet installed The use of these empty modules in the configuration avoids the need to change addresses later which can lead to problems especially in the application program if noe the RPI system has to be upgraded or expanded The defined empty modules are given in the device master file GSD file Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 7 2 9 7 2 9 1 Remote Process Interface Example Module type Explanation Ox1AO_INT_S KSD2 CO Ex 0 empty module RPI devices with 1 channel analogue output data signed integer data format with status information RPI device type KSD2 CO Ex Configuration of the Cyclic Communication Prior to configuration the GSD file selected for the RPI system should be copied into the prescribed direc tory of the configuration tool Having started the program the master for the PROFIBUS communication in a new
30. 5 6 2 2 5 6 3 5 7 5 7 1 5 7 2 5 8 5 9 6 RPI System Manual Table of contents Construction of the Gateways and LEDs on the Front Panel ccccceeceaeeeeceeeeeseeceaeeseeaeeseaneeeaeeeeeas Operating the Gateways Type KSD2 GW cccccccccecesseseceseeeeseceseeaeeeseaeeeeeeseanseeeessseseatasestesaseststssaseseees LO ALLOCATION OF THE DEVICE ADDRESSES ON THE INTERNAL BUS ssceccsscenccnecensennsenncnnsnnseuseneseusesescunsussenseussneseussens 76 CHECKING THE DEVICE ADDRESSES ON THE INTERNAL BUS usecessecnnscnnceenncnnnsencecnnsnnnsenseausseneseuseeueseneseusesnsenenenenses 76 SETTING THE GATEWAY ADDRESS ON THE EXTERNAL BUS uassssccnsccnnccnnccnncnnnnenncennnsnnnsneneenesnenseuseenescunseusseneseunsnnsenes 76 SETTING THE ADDRESS OF THE RS 232 RS 485 SERVICE INTERFACE usssccnsecnccnnnsnensnnecennsnensenssennsnensenssennseunseunsenes 76 Transier Rate of te Inte rial BUS acct wecsetecssaditwaducsadsauid deta cttewnsadencadessaadesadiodeauivediiusdssuiatteiytaiaiiasausalubadamdadceradiansauaadiun 16 SETTING THE TRANSFER RATE OF THE RS232 RS 485 SERVICE INTERFACE wssscesccnecsnnccennenensenssennsnensenssennsennseunsenes 77 SETTING THE TRANSFER RATE OF THE EXTERNAL MODBUS 1scssccseccenccnnnenncsenesnnsenssenssennsenneeussensseuseeusseneseunsenes 77 Setting the MODBUS Parameters cccccccsseccecesecceesececeeceseueeeseueceseueeessueesauecessueeessaeeessueessuaeessueeessesessaees 78 Teaching in Existing Confi
31. 65 67799091 Internet http Awww pepperl fuchs com 17 Remote Process Interface Safety 2 Safety 2 1 Safety Notes 2 1 1 Explanation of the Symbols Used in This Document This symbol warns of danger If the instruction given in this warning is not heeded the result could be the serious injury of personnel and or the severe damage or destruction of equipment Warning This symbol warns of a possible fault If the instruction given in this warning is not heeded the device and any plant or systems connected to it could develop a fault or even fail completely Attention T This symbol directs attention to important information Note 2 1 2 General Safety Regulations When used as related apparatus in accordance with EN 50020 the prototype test certificate and the national installation regulations must be observed Warning In addition all applicable standards directives and factory specifications as well as the relevant publications of the fieldbus user organisations as for example the PROFIBUS user organisa tion PNO ContronNet International etc should be observed Repairs to devices with intrinsically safe circuits should only be carried out by expertly qualified personnel following the appropriate regulations We strongly recommend that repairs should be undertaken by the manufacturers In the event of inadequate repairs being carried out Pepperl Fuchs GmbH will not honour the guarantee Subject to reasonable modifi
32. AEAEE E E OEE AA E E O E EEE E E Mounting tne FOWER RAIL FR 09 siiis EEE A EE REEE EERE Accessories for POWER FAIL PR 05 assosnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnna Combining the RPI System with Interface Modules from other Systems ccccsseeeccssseeeeeeeeeeeeeseneeeeeseeeeesaaanees KF Profile with Integrated Cable Ducts Human Machine Interface PAC TwareTM Edition 2 E actecter Interface adapter for RS 232 and RS 485 ou ccc cecccc ase ceeeeece acess eaeeeeeceeeeaeeseeaeseeaeeeeaaeeeeaeeseaaeeaeeeeaeaseees AGCCESSONES TOF API DEVICES sesno aa a o a a A i iE aerarii erraia Determining the Types and Numbers of Power Rails to be Used 1 ccseseceeeeeeseeneeeeneeeensneeeseaees Arrangement of the Power Rail Segments in a Control Cabinet cccecseeeeeceeeeeeeeeesaneneeseeneeneeaees acisi ACN oo A E E EE O EN E E E E A E E A E E General Information on Device Connection ss sessesreerernurrnrrensrrnrrrrrrnrrrnsrrnnrrnrrrnsrrnnrrnerrnrernerrenrenerrnere EMC Screening and Eating sisseisisiiicesverwaamasvsvadianietisenameneadounwarantenvaassucsuadedwedeeaiieneseeriemealauriatavencaleeavensd Preparing the Wiring Installing the Devices Connection to the Control Syston E E AET AE E E E E E E E E E EE E Connecting the Power Cables and Signal Cables 0 cc ccccceseececeececeeneeeaeeeeeeeeeeeseaeeeeaneeeesgeeenaneeeeeanenes C
33. Assembly of the UPR 05 Power Rail Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 51 4 8 1 4 4 8 1 5 52 Remote Process Interface Planning of the RPI System Figure 4 8 End clamp TS35 Type 12 Power Rail PR 05 Delivery package see Figure Figure 4 9 Insert component for standard top hat rails to DIN EN 50 022 length 500 mm Mounting the Power Rail PR 05 You should proceed as follows Shorten the Power Rail can be shortened as required at intervals of 40 mm at the points marked with indents It should be noted that there must be an end contact on the shortened component if shortened Power Rail sections are to be fixed together Extend The Power Rails are a standard length of 500 mm however they can be extended by joining them to another rail section using a VE PR connection fitting The two ends of the PR 05 are different A right hand and a left hand end contact should be used for the respective ends to allow the VE PR com ponents to be mounted Snap the end caps on the free ends of the Power Rail sections Insert the Power Rail sections into the top hat DIN rail If a number of power supply circuits are to be installed on one mounting rail segmentation of the power supply a separation of at least 1 mm should exi
34. By using a second gateway the bus connection to the higher level bus system can also be made redundant Gateways are available for the following stan dard busses e PROFIBUS DP e PROFIBUS DP V1 e MODBUS RTU e MODBUS Plus e ControlNet Voltage Supply via Power Feed Modules and Power Supply Units Special power feed modules are mounted on the Power Rail for voltage supply The number of power feed modules required depends on the current demand of the RPI modules the spacial arrangement and the need for a redundant design In case 24 V DC are not available suitable power supply units can be used They are designed to supply the Power Rail directly and can be mounted on the rail If the power supply units are mounted separately voltage supply takes place via the power feed modules RPI Devices The devices of the RPI system translate the signals of the connected field devices into the protocol of the RPI internal bus and vice versa In the case of devices with an intrinsically safe field circuit the signal line is safely galvanically isolated bet ween the hazardous and the safe area in the RPI device The signals for the hazardous area are intrinsically safe in accordance with ignition protection class ia or ib In addition a signal preprocessing can be set by means of a parameter assignment of the RPI devices HART Protocol Transmission The HART protocol is used to program HART compatible field devices These field devices are able
35. CI S Ex 3 XXX KSD2 C F x O 3 XXX KSD2 C0 5 Ex 3 MODUL KSD2 RO Ex2 evire Type fa Lhannek binay input part number Device Tyne Digtal output part number 35255 Vendor Peppetl t uchs Vendar Peppes uchs Set the structure of a project l COM fssy yes A new device is appended The new device is right behind the selected one 12 3 4 6 Configuring a device Select a device of the project and press the button config The clipboard view is closed and a configuration window with tab strips opened fe Peppert Fuchs K 56 Edit Project kg Project Edi Cobosd Options Retum Help lj xj Enumerate 3 XXX KSD2 B0 Ex Desonptor KKSD2BI Exd Dievane Tyne l4 Lhannets binary input part number Vendor Pepperl ruchs Set the structure of a project COM es BSU The first tab strip is Config It allows you to set the RPl Address of the device or the channel number if you have selected a channel It also allows you to type in a descriptor tag name for the device or channel lt may contain up to 28 characters This is helpful for larger projects to identify the devices clearly Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 205 12 3 4 7 12 3 4 8 12 3 4 9 206 Subject to r
36. FSD2 CO 5 Ex Disk Device Services Back Help Device Info Input Output Notes gt Tay Number Data Process Tag Mame Building 1 analog valve 11 Serial Number SS G00 Pat Number 22 Ghore address a 2 127 Parametration af a KSD2 00 5 E 7 Input 7 Output Mal Function Output Status hininvunn Lead breakage detection Software Revision io Hardware Piesis mu Unit ma Curent Range o 20 ma Upper Scale Value feu Lower Scale Value D o Short circuit detection DeviceInfo Input Output Notes Enter your notes here Two other example tab strips Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 209 Remote Process Interface K SK1 12 3 6 4 Setting a password The tab strip contains a part Password Panel You can set two different passwords here Both will be activated when you check the box Password active and save the information in the gateway You need to know only one password of the two passwords to get access to a protected gateway since both passwords are equal and have the same function O If you are using passwords avoid using empty password boxes Make sure that both pass words are set Note Device Info Communicat
37. Free space for system expansion RPI Devices DIN rail Power Rall Figure 1 1 RPI system In many production areas relating to process automation for example e chemical and petrochemical industry e pharmaceutical and cosmetic industry e paint production e food industry and e sewage treatment but also in production areas relating to factory automation there are plants in which a potentially explosive atmosphere exists In order to ensure protection and safety and guarantee proper functioning in safe as well as in hazardous areas RPI modules with intrinsically safe and non intrinsically safe field circuits are availa ble In the case of the intrinsic safety category of explosion protection these signal conditioners are desi gned as isolator modules which limit the electrical energy of the signal circuits in such a way that even under specified fault conditions the potentially explosive atmosphere cannot ignite Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 13 1 1 1 2 14 Remote Process Interface The Remote Process Interface RPI in Brief The RPI system can be installed in a control room with a safe environment or in the field within Zone 2 of hazardous areas Pepperl Fuchs recommends the PAC Tare software
38. Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 213 Remote Process Interface K SK1 the according error signal is set a non checked box means that the signal is not set SIM 6 Hebstelle 2 KSD Tl Ex Short Circus l _ Channel 1 2 Channel 3 4 e Dereal i l leak aye Channel T Short Circuit l low Singal warning I Lead Breakage high Signal Warning I Ehana 2 low Signal Alann I Short Circuit high Signal Alame I Lead Breakage J Signal under Measuring Range l Signal over Measuring Range _ Two examples of channel specific diagnostic windows The content is device dependend 12 3 11 Other program options 12 3 11 1 Setting basic program options Select Options Setting to set basic program options If you have selected Project manager always on top the project manager window is always dis played If you do not check this option the project manager window is closed when you open a diagnosis or a monitor window The option connection establishment read tag names on connection determines whether additional information is transmitted between PC and gateway during the connection establishment or not gt Pepperl Fuchs K SK 1 7 TEST PRJ OL x Project Connection Display Diagnostic Device Data Options Exit Help S Resouces 61 TEST PRJ I Host IBM PC or compatibl
39. GENTAN ae sire wena cine cena A secu anion sin EAE E E EEE Computer TE lated TONT eee ee ee eee ee eee eee ce eee eee ee ee ee Hardware requirements ccccccccccecceseeccecseseeseeceenceaeeseesceaenaeeaeeaeeaeeeseaeeaaeeseeeeaneeseessageesesesageeaeeanesengenanes Operandi oae E E E A cceeeeucneseee Stalan VOCOSS ss cadraterevcctsacec cnac atelesineicu a ENEA ae 198 USING TNE SOM WANG sap na eaccseneseacouns cceecwescectsnteecasenwosaeacaseatondsiact auanseaesadenctantace T he advantage Of USING software ccececcceececeaneseceenceceseseeceauscesusaeeeaueseeseseeseseaeeseaaeesanseeessaesesanssessags Setting up a complete system ecc ce seecessseeeceeeececeaeeceaueeecusaeeceseseeceaueeecuseeseaaeseeseeeesssneeessaatesseeseessaneess Monitoring and Diagnosis ssessnesenene nne ceeeneece ee eeeee cess ceeeeeeeeee aces antt ae ee ae eeeaa cess ce eeseeeaeeeeaseaeeaesesaneneaneees Changing SYSTEM information cece ce eecce cs eeee cee eececeaeeceeaeecauseeeceaesceaesnececueaeausaeeceaeseeauaneeeaneseesuseessaneeeenas KeSK 1 Op r tion manual s issis aa aa aaa aaa araa i iaaa aaa Starling WIS SOMWGRC sessirnar a a a e a R RAER TAP TIA UA SGT saia a e E EEE E E E E E ee ee ee A A E TE EE eee 199 Seep E EE E IEA AET A EE E L T 199 EE A A E E A E T 200 PER E E E TE E E E E E E ace 200 ee E A E ee ee ee Cee 200 gi eect A PEA AA A A ee ete eee eae 200 Di eset rece EEEE E A aes ees eee dees ees eee 200 The proj
40. Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Input Data Area The data structure of the input area depends on the configuration of the RPI modules It may contain up to 215 words Further information can be found in the ControlNet Gateway Users Manual 7 5 7 Command Response Transmission The command response is transferred by means of the ControlNet unscheduled service acyclic data ex change The host transmits a command to the gateway and the gateway transmits the response back to the host The commands available Command word are given in the list below Further information can be obtained from the User Manual e Command Word 2 Set I O data structure e Command Word 3 Set redundancy mode e Command Word 4 Read module diagnosis e Command Word 5 Single channel function diagnostics e Command Word 6 Read error code and RPI device alarms e Command Word 7 Read gateway ID list e Command Word 8 Read RPI system module types e Command Word 9 Read error code and channel alarms Format Command and response are transmitted in the 16 bit integer format The data length depends on the com mand and the response It varies from Command Word to Command Word re Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore
41. Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 187 188 10 11 12 13 Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Remote Process Interface Quick instructions Start PACTware You start the PAC Tware human machine interface on your PC Your PC its COM port interface your gateway and depending on the circumstances other devices are symbolically represented in the left window of the main menu If this is not the case then click on Button 2 in the window Parameterizing the COM Port Parameterize the COM port by setting the COM port on the PC notebook and the baud rate of the serial interface in the dialogue window tab Parameterizing gateways Parameterize the gateways by entering the gateway address the baud rate and the parity stop bit You enter the data into the white fields of the dialogue window tabs Two code words can be used to provide protected access Each of these ensures full access to the system Always assign both code words If one code word is left blank it increases the risk of access by unauthorised persons If you click on Panel locked you will not be able to make changes later with the gateway buttons Therefore this item should not be sel
42. Remote Process Interface Reading binary input data with status This data is deposited in register table 4 which can be called up via the function code 04 This data is exclusively represented as device based The switching state bit 0 and 7 status bits bit 1 to 7 are available in one data byte The exact structure is shown in the following table awe ai Dal Bits GW1 and GW2 are of no significance for binary inputs CD1 to CD3 code the error that has occurred Q1 and Q2 provide information on signal quality O Analogue input data is usually read from the input registers of a Modbus station by PLC s or il process control systems In exceptional cases it may be that control of access to the input register is not supported In this case the correct register addresses can be obtained from wer Chapter 7 3 13 Three error messages are generated for the binary data the significance of which is given in the following table Internal memory or interface error CS eet Tt ee ae CCE NNN Sensorerror CUT Ot Of Ot Of The first two lines indicate an error in the RPI device The third line indicates a lead breakage or short circuit where this information is only generated if the option s lead breakage monitoring or short circuit monitoring is are activated on the device Further details can be found in PAC Tare or in Section 12 of this handbook RPI devices with a maximum of 4 channels with status 2 registers per RPI device The dat
43. Start End Output Malfunction Output Status Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Remote Process Interface Parameter Assignment The entered address must be identical with the address set on the relevant device It allows you to type in a descriptor tag name which may contain up to 32 characters This is helpful for larger projects to identify the devices clearly In this box the input signal can be assigned a physical unit The zero point of the input signal is defined by selecting the cur rent range The sensor lead is monitored for lead breakage The sensor lead is monitored for short circuits If you check the left box by clicking into it you activate the warning limits Now Lower Limit and Upper Limit turn from grey to black The limit values are entered into the boxes on the right hand side If you check the left box by clicking into it you activate the alarm limits Now Lower Limit Upper limit and Hysteresis turn from grey to black The limit values are entered into the bo xes on the right hand side The start value needs to be entered in order to be able to scale the measured value The final value needs ot be entered in order to be able to scale the measured value Example The current range is 4 20 mA and the measuring ran ge
44. Subject to reasonable modifications due to technical advances Remote Process Interface Planning of the RPI System Functionality all available DTMs for Pepperl Fuchs K and E Devices HART multiplexers Remote I O systems RPI and IS RPI and Level Control devices Restricted functionality no printing no saving Professional Level license for all available DTMs for Pepperl Fuchs Level Control devices Professional RIO100 license for the connection of 100 measuring circuits to Pep perl Fuchs Remote I O systems RPI and IS RPI including HART multiplexers Professional RIO500 license for the connection of 500 measuring circuits to Pep perl Fuchs Remote I O systems RPI and IS RPI including HART multiplexer Enterprise license for all available DTMs for Pepperl Fuchs K and E devices HART multiplexers Remote I O systems RPI and IS RPI and Level Control devices Unlimited number of devices measuring circuits and systems in a project can be ope rated Access to all device parameters via serial interface via HART communication or by means of acyclic field bus communication lt 007 gt KSD2 TI EX Parameter E loj xj Device address Address f7 Channel 1 Tag data gt Tag name Sensor 7 Sensortype Pt 100 Lineareation table Unit E Wiring 3 wite lt Ze cairan Lead breakage detection Short crcut detection Limit PE Waming limits active 7 Alame limits active Limits of measuring range
45. Summary of RPI Modules Currently Available ote Construction of the Power Feed Module LED red Fault signal LED green Power Fine wire fuse Type T Figure 4 6 Front view of power feed module KFD2 EB RPI and KFD2 EB R2A RPI Dual designed power feed terminals enable the external supply voltage to be daisy chained The presence of the operating voltage is indicated by the green PWR LED on the front panel of the device Group Fusing on the Power Feed Module The fuses on the front panel of the power feed modules protect the contacts for the Power Rail from over load and serve to provide group fusing for the RPI devices of each Power Rail segment In addition each RPI device is internally fused A fault of the fuse of the power feed module is optically indicated on the red LED on the front panel In ad dition external indicators can be triggered via an internal relay The relay operates as normally open con tact as standard the direction of operation can be adjusted by means of a plug in jumper see Chapter 5 2 2 Setting the Mode of Operation of the Relay Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 47 4 7 3 4 7 4 4 7 5 48 Remote Process Interface Planning of the RPI System Segmentation of the RPI
46. System The RPI devices of a gateway can be mounted at different isolated Power Rail segments The internal bus and HART protocol transmission can be daisy chained by connecting the individual termi nals to the power feed modules KFD2 EB RPI and KFD2 EB R2A RPI e Internal bus Connection of terminals 12 13 and 15 e HART protocol Connection of terminals 14 Power Feed Modules for Redundant Power Supply If required the power supply can be given a redundant layout As a rule both the supply power systems or power supply units must be decoupled via diodes The KFD2 EB R2A RPI power feed module incorporates decoupling diodes and can provide a supply of up to 2 A The KFD2 EB RPI power feed modules and the KFA6 STR 1 24 4 power supply unit provide a voltage of 24 V DC and a maximum of 4 A However they do not have a decoupling diode When using external decoupling diodes the KF D2 EB RPI power feed mo dule can also be used for a redundant power supply Setting up the Power Supply Balance for the RPI Devices Including the Gateways To size the power supply required calculate the maximum current consumption of the RPI modules The data sheets contain data on the power consumption and the voltage supply range for each device The ma ximum current consumption always occurs on the RPIs of minimum power supply i e for a power supply of 20 V Inthis way the maximum current consumption must be calculated for each RPI device used inclu ding tha
47. Where to Install the RPI System The RPI system can be installed either in the safe area of the control room or in the zone 2 hazardous area of the plant The installation of the RPI system within Ex zone 2 must be undertaken with due regard for the statement of conformity T V 00 ATEX 1617X or T V 00 ATEX 1618X Only devices with an appropriate statement of conformity can be installed in zone 2 Detailed information is given in Chapter 2 6 Declaration of Con formity Planning the Transmission of HART Protocols HART stands for High Addressable Remote Transducer It is a digital communication protocol for the trans fer of data to sensors actuators and field devices These devices can perform calculations self diagnoses and error reports RPI offers three possibilities to communicate with HART compatible field devices Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Planning of the RPI System 4 2 1 Direct Connection of a HART Programming Unit up to 250 field devices sensors or actuators HAR I devices e g KSD2 CO 5 Ex H Nv Connector for programming device Figure 4 2 Programming Unit The field devices should be connected to appropr
48. Windows 95 and Windows NT 4 0 Installation process Insert disk 1 into a disk drive and start Setup exe An installshield guides you through the remaining instal lation process Using the Software T he advantage of using software K SK1 let s you configure a complete RPI system or upload an existing configuration The advantage of the software is that you can multiply this configuration as many times as you want This is a valuable feature in production processes Setting up a complete system The recommended way of setting up a complete RPI system is to plan the structure of the system with a PC The gateway and all devices are configured first in the PC then the hardware in the control cabinet is set up After configurating the project in the software you have to download the configuration into the gate way When setting up the hardware you can do it in either one of those ways Download all device information at your desk then insert the devices into your cabinet Or insert your con figured gateway into the control cabinet and add the devices in the order of your project Monitoring and Diagnosis K SK1 allows you to monitor the state of the devices connected to your PC via the gateway You can also have a diagnosis of the connected devices or simulate their inputs and outputs or their error messages re spectively Changing system information You can edit the information stored in each device by software K SK1 also allows y
49. address Device based max 4 channels 3 2 RPI address 3 3587 2 registers per device Device based max 8 channels 3 4 RPI address 3 3084 4 registers per device Analogue inputs without status Reg Tab Signed integer format Floating point format Analogue inputs 1 channel device RPI address 4608 2 RPI address 3 6150 Analogue inputs 2 channel device 2 RPI address 3 5126 4 RPI address 3 7052 Analogue inputs 3 channel device 3 RPI address 3 12 6 RPI address 3 8210 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Analogue inputs with status Floating point format Analogue inputs 1 channel device 3 RPI address 3 6409 3 RPI address 3 5641 5 RPI address 3 7567 6 RPI address 3 2072 8 RPI address 3 536 Analogue outputs without status Reg Tab Signed integer format Floating point format Analogue outputs 1 channel device RPI address 4608 2 RPI address 3 6150 Analogue outputs 2 channel device 2 RPI address 3 5126 4 RPI address 3 7052 Analogue outputs 3 channel device 3 RPI address 3 12 6 RPI address 3 8210 Analogue outputs with status Analogue outputs 1 channel device 2 RPI address 3 4742 3 RPI add
50. at 4 bytes 32 bit and the memory block is classified as follows Bit position Meaning 31 Sign bit MSB 1 Byte LSB MSB 2 Byte LSB ties Ooo Mantissa Exponent Sign bit The sign bit 31 indicates whether the stored number be positive s 0 or negative s 1 The 8 exponent bits constitute the exponent However a BIAS of 127 has to be subtracted from each exponent In other words in the exponent a bit sequence of 111 1111 corresponds to 127 stands for exponent 0 The 23 ma tissa bits represent the 23 fractional digits of a 24 digit binary number The first digit before the dual point is always 1 It is not stored The following table provides examples of simple floating point numbers Binary notation Sign Exp Mantissa Meaning 0011 1111 1000 0000 0000 0000 0000 0000 127 127 1 00 gt 20 1 00 1 0100 0000 1010 0000 0000 0000 0000 0000 129 127 1 25 gt 22 125 5 1100 0001 0101 0000 0000 0000 0000 0000 _ 130 127 1 625 gt 23 1 625 13 0100 0001 1000 0100 0000 0000 0000 0000 131 127 1 03125 gt 24 1 03125 16 5 125 635 0100 0010 1111 1011 0100 0101 0000 0000 4 433 497 4 9630469 gt 26 M 125 635 Integer format 2 byte are required to transmit the measured values in the signed integer format Likewise 2 byte are re quired in order to represent numbers from 32 768 to 32 767 in the signed integer format In order to achie ve a more accurate transfer of the data temperature measuremen
51. be automatically overwritten and repla ced with the planned project address by the gateway thus considerably simplifying the commissioning and replacement of the devices You can give the address 0 to a device that has another address Snap the device onto a mounting rail containing a Power Rail and having a power supply but without a gateway Press the ADR button on the device until the green PWR LED flashes Deleting an Existing Gateway Configuration from Version 1 4 From gateway version 1 4 onwards it is possible to delete an existing gateway configuration Snap the ga teway onto a mounting rail containing a Power Rail and having a power supply but without any other de vices mounted The LC display shows SYN Now press the Mode button for longer than 3 s The INT LED goes out The set configuration and all other device data stored in the gateway are deleted Redundant Power Supply The 24 V DC power supply can be laid out as aredundant system Both power supplies can be fed together via a single power supply module or via two separate power supply modules on the Power Rail Special power supply modules are available having decoupling diodes which avoid interference between the two power supply nets see Interface DIN Rail Housing catalogue Redundant Internal Bus System The internal bus system always has a redundant layout The failure of the bus system and switch over to operation via the redundant
52. be checked by simulating the input values without connecting a process peripheral The actual measured values of the simulated circuit are overwritten by the simulation data if a process pe ripheral is connected The data exchange with the other non simulated devices is not interrupted by the simulation 8 3 2 Simulation of Output Signals By simulating the output values the actuators in the field e g valves pumps motors can be checked and adjusted without a control system connected The signals of the simulated measuring circuits are input from the human machine interface Output signals from the control system are suppressed for the simulated measuring circuits The data exchange with the other non simulated devices is not interrupted by the simu lation O The simulation of a device can be carried out during operation u During the simulation the error code 08 device being simulated is displayed on the gateway ote LC Display and the red LED internal bus fault flashes Up to 5 devices can be simulated simultaneously rable reactions in the control system i Simulation plays an active part in a process A simulation of the input values may cause undesi A simulation of the output values initiates the actuators opens valves and controls pumps Attention A check should be made in any case prior to starting the simulation that no system endange ring or undesirable conditions are likely to arise x am
53. between E Error and an error code that indicates the type of fault that has occurred Operate the or Ii buttons a number of times in order to establish whether any other devices have a fault condition Error codes 01 There is a device in the gateway configuration that is not available on the internal bus 02 A device is present on the internal bus that is not in the gateway configuration 03 Incorrect type of device 04 Device error 05 Channel error e g lead breakage or short circuit For the channel number see the flashing red IN CHK or OUT CHK LED on the indicated device 06 The device is in the initialisation phase 07 Address conflict 08 The device is in the simulation mode 81 Loss of redundancy internal communication 82 Loss of redundancy external communication 83 Loss of redundancy user initiated 84 The check sums of the parameter sets in the active and passive gateways are not the same Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 189 10 5 10 6 10 7 10 8 10 9 10 10 10 11 190 Remote Process Interface Quick instructions To Replace a Device while the System is in Operation If a device is to be replaced the system must first have been set into operation from th
54. by Means of KSD2 GW2 Gateway ccccccccseeeeeeceeeeeeeaeeeeeecaaeeeeeceaeeeeeeeaeeeessaceeeesaaeeeeesaeeesessnsees 89 Assignment of the Device Address for the Internal BUS ccccscececeeeeceseeeeseeeeeaneseesaseseesseetessaessstsseees OD ADDRESS ASSIGNMENT BY MEANS OF KSD2 GW GATEWAY wssscccsscsnsenccennsnnnscussenesennecunseneseneceneseensenensnesseussnnes 89 ADDRESS ASSIGNMENT BY MEANS OF KSD2 GW2 GATEWAY sesssssssensencccnnsnnnsenesenesenneenssennsenenenessensenensensseussnanes 89 Assignment of the Neutral Device Address 0 for the Internal BUS c cc ccccceececeeeeeceeeeseeeeaeeeeeaneeeaneees Configuration of RPI Devices with Automatic Address Assignment Using PACTwarelTM Configuration via the Service Interface ccc cececcaecececneeeeeseeeeeseeeeeeaaeeeaeeeaeeaeseeseeeeeese sense eeeaeeseeeseeeesanes Acceptance of the Configuration and Parameter Assignment of an Existing RPI System 00008 Gateway Type KS D2 GW ree cteaptctesedececien eed aslecenenteinctdeuccaicneeihataendasmpsntnpned ex euienandeessiisesndeneancqacesqedennsicnn thease basenecsteneceasts Gateway Type avo Ba 2 aero ee ee ee eee ee eee Checking the Configuration and Parameter Assignment cccceseeeceeneeceneeeeceaeeeeaneeeaeaueeeeaeseeeeaneeeanaaes ONHNE COMMISSIONING iscrisse aaraa Fully Mounted RPI system ccc ceccce seen en eeeeeeeseae sess eessenesssseeeeaceaesseeeeeseaeenea
55. contain up to 215 words The configuration of each RPI device the data format and the transfer of the status byte can be defined using Command Word 2 Additional information can be obtained from the ControlNet Gateway Users Manual Structure of the Input Control Area Register Byte Description of the Read Holding Register Low Q Dy O Response Counter Echo of the Command Counter if the response to a command for transmission in the ae is complete Input Update n nter Counts n of the input data in the input data field Low RPI a Counter a counter for status change of the RPI A change in the counter indicates either an error status change in ERROR_CODE LIST or achannel alarm status change in CHANNEL_ALARM_ LIST RPI Parameter eee a counter for each gateway parameter w ooo RPI configuration error Bit 0 RPI configuration error Bit 1 reserved Bit 2 reserved Bit 3 RPI device error Co Q 3 3 a diagnosis Bit 0 E2PR_Err Bit 1 APPL_Err Bit 2 WATCHDOG Bit 3 TIMEOUT COM Bit 4 not used Bit 5 not used Bit 6 not used Bit 7 reserved Bit 4 RPI channel error Bit 5 Redundant circuit Bit 6 Redundant mode Bit 7 Parameter check reserved Q D a oO Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091
56. daz on compatitile COM IEOH Pot API H dii KSD2 Gw PAO T 1310X KSD2B0 Ex 3 MODUL KSDZ Bl E ad A PON KSD200 Fx Gat the atractuen of pajek You can choose the details of information by selecting different structure levels The picture above shows a device tree in level 3 and level 4 The Show details check box D If you check this box by clicking into it the project manager window separates into two parts The lower part provides you with additional information about the selected item of the top part You deactivate this option by deselecting the check box Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface K SK1 P Pepperl Fuchs K 5K 1 7 TEST PRJ Project Connection Ciepap Ujsersstc Device Data Options Exit Help Fa Monito F4 Diagnostic paag Resources 635 IESI_PHJ 1 A Host IBM PC or compatible LiF COM 1 COM Port AP Up 4 Building 1 analog valve 1 KSD2 CO 5 Ex jo AA ROD LI S Ex G Mefstelle 2 KSD2 TI Lx A Mefistelle 17 KSN2 Al Fx 13 KSD2 Bl Ex4 poe KSD2 BO Ex 12 3 3 Handling the project You need only a few functions to fully handle a project in K SK 2 Besides opening and saving a project the
57. flexible cables with plastic wire end ferrules The screw terminal blocks on the device can be removed for ease of connection Mount the gateway on the Power Rail and connect the Modbus cable and if necessary the RS232 RS485 cable as described in the connection plan and the terminal assignment list The connection plan for the RS232 or RS485 gateway can be obtained from the current issue of the Inter face DIN Rail Housing catalogue Sub D connector Terminal a KSD2 GW MOD 485 Screen RS 485 2 RXDIT30 B RSAS5 param interface XD P_ RS485 param iera 3 RD TD N RS485 param interface RxD TxD N RS485 param interface Terminal assignment Terminal a KSD2 GW MOD 485 RxD TxD P RS485 param interface 8 TxD S292 param Interia RXD TXD N R485 param interface go e e RSS O The number of stations on one RS485 interface Modbus interface such as the RS 485 pro il gram interface is a maximum of 32 as standard Note The maximum length of lead on a bus segment is effectively determined by the following parameters e Type of bus cable used e Transfer rate e External interference effects e Number of bus stations More detailed information on the determination of the maximum lead length can be obtained from the EIA 485 or ISO 8482 Bus termination On the Modbus Plus each bus segment must be terminated by resistances at both ends of the il line Note Subject to reasonable modifications due to technical advances Copyri
58. gt down on the left 3 Select lt Project gt in the menu bar and then lt Device catalogue gt or press function key F3 after which the device catalogue appears in the edit window It contains all the installed Device Type Managers in a Windows Explorer representation By highlighting the desired position in the project tree and then double clicking onto a device the latter is pasted into the project If you select options 1 or 2 a selection window offers you only those options that can be pasted to the selected position Click onto the desired Device Type Manager in the selection window and confirm your selection using the lt OK gt button or double click the desired Device Type Manager If you wish to use the device catalogue point 3 given above the screen separates into three parts The left part shows the project tree The middle part shows the DIM components structured according to their functions and installed on your PC using PACTware The right part lists the entire device catalogue O In general the following applies to projecting Only those devices can be selected from the il device catalogue whose model numbers correspond to the devices used in the RPI system PACT are does not permit the connection of Device Type Managers unless they are useful on Note the relevant position in the project tree Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Peppe
59. has been installed step 1 the RPI devices must be addres sed The information required for this procedure is given in Section 5 of this handbook The following sequence should then be carried out 1 Mount a gateway on the Power Rail and set the RPI address of this gateway to 1 active gateway Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 137 7 3 4 138 Remote Process Interface 2 Teach the current configuration into Modbus A 3 Load the project into the gateway download using the PACT are software 4 Mount the 2nd gateway on the Power Rail and set the RPI address of this gateway to 2 redundant gateway 5 Connect the PC to the redundant gateway and then repeat steps 2 and 3 for the redundant gateway If the project has been downloaded into the redundant gateway the system is ready for redundant operati on When both gateways have been configured the type and method of switching from the active to the redun dant gateway must be established This takes place in register table 3 register address 4360 where the following modes can be set Value Description OOh No redundancy ming defective 02h Switch over to the redundant gateway by the host see gateway diagnosis 03h Switch over of the passive gateway into the acti
60. interface To enable the gateway to communicate with a PC as PROFIBUS master class 2 via the external bus it is necessary to integrate a communication Device Type Manager DTM This DTM enables PAC Tware to carry out the configuration and parameter assignment of the RPI system by means of an acyclic data exchange via the master class 2 1 Setthe transfer rate and the gateway addresses depending on the bus system using the pushbuttons The information required for this procedure is given in Chapter 7 2 Gateways for PROFIBUS DP on Page 114 2 Insert the communication DTM into the offline project Configuration and Parameter Assignment via PROFIBUS DP and GSD 0818p gsd Alternatively the devices can be parameterized device by device using the GSD file This procedure is de scribed in Chapter 7 2 Gateways for PROFIBUS DP on Page 114 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 6 1 6 1 1 6 1 1 1 6 1 1 2 Date of issue 05 27 03 Remote Process Interface Parameter Assignment Parameter Assignment Parameters of the RPI Modules The individual RPI devices can be parameterized by means of both the human machine interface PAC Twa re M edition 2 or a different configuration tool In the case of PAC Ta
61. max core cross section 1 x 2 5 mm for rigid cables or 2 x 1 5 mm for flexible cables with plastic wire end ferrules The screw terminal blocks on the device can be removed for easier connection Mount the gateway on the Power Rail and connect the coaxial cable and if necessary the RS232 RS485 service interface cable The connection diagram for the gateway with RS232 or RS485 interface can be obtained from the current issue of the Interface DIN Rail Housing catalogue Connection type on the front Connection KS D2 GW CN 485 BNC plug for ControlNet BNC plug for ControiNet BNC plug for Controle BNC pug for ContoNet NaP amp pin RJ 45 connector for configuration tool 8 pin RJ 45 connector for configuration tool Terminal assignment Terminal ASDAGWEN O GW CN KSD2 GW CN 485 RxD RS232 param interface RxD TxD P RS485 param interface 23 T0 RS22 param interface XDIT3D N RS485 param interace a orsz nse o C S C tH O The number of stations on one RS485 interface Modbus interface such as RS 485 parameteri zation interface is a maximum of 31 as standard Note The maximum length of lead on a bus segment is effectively determined by the following parameters Type of bus cable used Transmission rate External interference effects Number of bus stations More detailed information on the determination of the maximum lead length can be obtained from the EIA 485 or ISO 8482 Subject to reasona
62. mounting rail Figure 4 10 KF Profile The KF Profile is available including the PR 05 Power Rail It will accept up to 90 RPI modules over a length of 1 8 m in a space saving installation with simple provision for wiring In addition the KF Profile is available with a lateral shunting bridge The KF Profile has the following advantages e Very high packing density in the control cabinet installation since the cable ducts are integrated in the mounting profile e A saving in installation costs since the cable ducts are integral and do not need to be mounted separa tely In addition Pepperl Fuchs offers preconfigured cables see DIN Rail Housing catalogue e Since onthe Remote Process Interface the wiring to the control system is almost completely eliminated the separation between the non Ex connections of two installation lines can be very small thus further increasing the compactness of the installation in the control cabinet Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 54 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Planning of the RPI System 4 8 3 Human Machine Interface PACT are Edition 2 PACT ware Process Automation Configuration Tool configuration tool with FDT interface Fi
63. not active OQ O J Yellow LED input output channel 1 active OO EO O O O Red LED lead breakage or short circuit of the field circuit channel 1 LED 1 red and ERR LED EEPROM error LED 1 yellow and ERR LED communication error Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 197 12 12 1 12 1 1 12 1 2 12 1 3 12 1 3 1 12 2 12 2 1 12 2 2 12 2 3 12 2 4 12 3 12 3 1 198 Remote Process Interface K SK1 K SK1 THE MAN MACHINE INTERFACE FOR THE CONFIGURATION PARAMETERISING SIMULATING TESTING AND MONITORING THE RPI K SK1 General Computer related font Computer related items like keys software buttons menu items etc are written in courier font The presentation of menu items ismenu menu item If the menu item is depending on the active window but unambiguous it is represented by menu The and 8 symbols note that the described action relates to that input device Hardware requirements Torun K SK 1 you need at least an IBM compatible PC with 486 CPU 8 MB RAM 16 MB RAM recommen ded 5 MB free harddisk space and a free serial port Find out the COM port number of this free port since you have to set up your software accordingly Operating system K SK1 runs under Windows 3 x
64. or achannel alarm status change in CHANNEL _ALARM_LIST Low RPI Parameter Counter a counter for gateway parameter change RPI configuration error Gateway diagnosis Bit 0 RPI configuration error Bit 0 E2PR_Err Bit 1 reserved Bit 1 APPL_Err Bit 2 reserved Bit 2 WATCHDOG Bit 3 RPI device error Bit 3 TIMEOUT COM Bit 4 RPI channel error Bit 4 not used Bit 5 Redundant circuit Bit 5 not used Bit 6 Redundant mode Bit 6 not used Bit 7 Parameter check Bit 7 reserved reserved O gt Further information about the Functional Commands and the tools can be obtained from the Modbus Plus Gateway User Manual Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface 7 5 Gateways for ControlNet 7 5 1 KSD2 GW CN and KSD2 GW CN 485 Gateways The KSD2 GW CN and KSD2 GW CN 485 gateways are designed in accordance with the international ControlNet specification for Communication Adapters profile No 12 The KSD2 GW CN gateway has an RS 232 service interface while the gateway of the type KSD2 GW CN 485 has an RS 485 interface The operating level consists of an LC display with 3 1 2 digits and of the three pushbuttons Mod
65. package as human machine in terface for commissioning and operation of the RPI system This software allows a simple configuration and parameter assignment of the RPI system by means of a PC notebook directly on the system or via a statio nary engineering console in the control room A functional RPI system consists of 1 Top hat DIN rail for mechanical installation with Power Rail for voltage supply and internal bus con nection of all modules 2 Power feed module for coupling and monitoring the voltage supply In the case of 24 V DC power sup ply no power supply units are required 3 Gateway for coupling the system to one of the external bus systems PROFIBUS DP or PROFIBUS DP V1 eMODBUS RTU or MODBUS Plus eControlNet 4 RPI devices for both intrinsically safe and non intrinsically safe field circuits are available for the follo wing applications eAnalogue input 0 4 to 20 mA with or without transmitter power as well as with or without HART pro tocol transmission eAnalogue input for resistance thermometers thermocouples potentiometric recorders and mV transmitters eAnalogue output 0 4 to 20 mA with or without HART protocol transmission Binary input for mechanical contacts and proximity switches eBinary output for solenoid valves eBinary output for a potential free relay contact 5 PC adapter for RS232 or RS485 as well as a suitable configuration software A Please refer to Chapter 2 2 Intended Use and Chapter 3 1 S
66. plant is not guaranteed if the equipment is used for a purpose for which it was not intended The Remote Process Interface must only be operated by authorised specialist personnel in ac Warning cordance with this equipment documentation handbook data sheet certificate of conformity The handbook constitutes the operating instructions in accordance with the Equipment Safety Law 3 3 It applies in conjunction with the appropriate data sheets of the RPI modules 2 3 Installation in a Potentially Explosive Atmosphere The Pepperl Fuchs Remote Process Interface can either be installed in a control room in the safe area or in the field within zone 2 of the hazardous area See chapter 2 6 Declaration of Conformity It is suitable for intrinsically safe signals of zone 1 or 0 and for non intrinsically safe signals Definition of Ex zone 2 AN An area in which during normal operation a potentially explosive gas atmosphere does not oc cur but seldom and only for a short time Attention According to the approval the installation of the RPI system within zone 2 of the hazardous area requires the installation in a single housing of protection class IP54 or higher Installation of the RPI system with a voltage supply in zone 1 can be carried out in a pressurized housing For detailed information please refer to Pepperl Fuchs GmbH Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germ
67. proceed you are asked to choose the features you want to simulate There are three options available Process Value Device Specific Diagnostic and Channel Specific Diagnostic Selection Ea Please select the simulation mode requmed f Process value Device specific diagnostic f Channel specstic Diagnostic 12 3 10 3Process Value If you choose Process Value you are allowed to change the state of the inputs and or outputs Select the feature and confirm with OK S SIM 13 FSD TAG 1 ca achu CI ted You change the switching state of binary inputs outputs by clicking onto the according switch or the led of the state you want to set With analogue devices you will find a drag bar to change the values Just drag the button to the desired value or write down the value into the according field 12 3 10 4Device specific diagnostic With this option you simulate the error signals of the devices E2PR_ERR I APPI FRR WATCHDOG Timeout Communication l Intemal Redundancy active Local Access Parameter E rror l The simulation is straight forward a checked box means that the according error signal is set Reset the signal by clicking into the box again 12 3 10 5Channel specific diagnostic The function principle is the same as with the device specific diagnostic Again a checked box means that Subject to reasonable modifications due to technical advances Copyright Pepperl
68. project has to be sel ected and the hardware is to be configured By inserting the CPU or the communication module the pro perties of the PROFIBUS stations such as PROFIBUS address baudrate and the profile can be set Representation of the Gateway in the DP Master System On opening the GSD file the RPI structure tree is reproduced in the configuration tool in order to establish the communication This is done by selecting the gateway from the GSD file list and adding it to the master system By adding the gateway as a DP slave the PROFIBUS address is automatically assigned The latter must correspond either to the external address in Mode d or to the one in the Address Assign service menu on the gateway The PROFIBUS address can be changed and adapted to the gateway address When a second gateway is used redundant gateway the RPI structure tree of the priority gateway is co pied and pasted to the redundant one The addresses of the two gateways must differ this does not apply to redundant gateways operated at high availability control systems The settings for the four user parameters of the DP slave must be selected according to the details listed below Acyclic access via the cyclic data channel module 0 access This functionality is not specified in this handbook Signed Integer or FLOAT format for analogue values Operation with or without redundant gateway With or without status transmission O Please note that
69. rameters and values no flashing flashing OK OK PARAM 192 192 ADRESS e BALD Esc BALD t Up Down o k accept value 19 6 esc reject value BALD t Up Down e Figure 5 11 Changing parameters and values 5 4 3 9 Teaching in the RPI Configuration Teach In Service Menu The current configurations of all connected RPI devices are uploaded to the gateway by means of Teach In Existing parameter data of the devices is likewise uploaded This function helps you to start up the RPI rapidly or to teach in hardware changes However you have to ascertain that you keep track of these changes in your software human machine interface O ial Bear in mind that you can use the human machine interface to keep track of the set up of your project Note In PAC Tware this is accomplished using the Project upload function 5 4 3 10 Assignment of Device Addresses AdrAssign Service Menu The Address Assign menu is used to transfer the desired address for an RPI device on the gateway e Set the desired address using the Up and Down buttons Only free addresses are indicated e The address is transferred to the RPI device by depressing the ADR pushbutton on the front panel of the device that is to be addressed for longer than 3 s e The green LED on the gateway flashes for a brief period the display of the gateway shows the next free address Subject to reasonable modifications due to technical advances Copyright Pep
70. registers have to be read written in order to access the data from an RPI device The data is constructed as follows Register address 1 Register address Channel 2 Channel 1 In the floating point format 4 registers have to be read written in order to access the data from an RPI de vice The data is constructed as follows Channel 1 Register address 1 Register address Channel 2 Channel 1 Channel 2 Register addresst3 Register address 2 Channel 2 Channel 1 Data for unoccupied channels is set to 0 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Writing reading analogue input data 3 channel devices All measured values from 1 2 and 3 channelled devices are represented in this area as a function of the current RPI address The register addresses can be obtained from the following equations Data format Register address Signed integer 3 RPI address 3 12 Floating point 6 RPI address 3 8210 In the signed integer format 3 registers have to be read written per device The data is constructed as fol lows Register address 2 Register address 1 Register address Channel 3 Channel 2 Channel 1 In the float
71. signal transferred to the control system in the error case is determined according to the application For the setting As Input a value should be entered in the box on the right hand side The Parameter tab contains both device specific and channel specific parameters 2 lt 005 gt KSD2 CO S EX H Parameter E iol x Device address Address 5 x Channel 1 Tag data nput Signal range Lower 4 0 7 m Upper 20 0 m Lead breakage detection Output output status Help Figure 6 16 Parameterizing KSD2 C0 Device Address Tag Data Tag Name Input Unit Current Range Lead breakage detection Short circuit detection Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 e USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 107 Tag name Unit ma v Current range 4 20 m Mal function Minimum ha Value Short circuit detection The entered address must be identical with the address set on the relevant device It allows you to type in a descriptor tag name which may contain up to 32 characters This is helpful for larger projects to identify the devices clearly In this box the input signal can be assigned a physical unit The zero point of the input signal is defined by selecting the cur rent range The sensor lead i
72. technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 11 3 Error Messages on the Gateways via LED LED red Communication _ LED green Power supp LED red Internal communication LC Displa LED yellow red External bus Button Up Button Down Mode button Rotary switch termination resistor for PROFIBUS RS 232 3 5 mm Jack bush Removable terminals green Figure 11 1 Front View of the KSD2 GW and KSD2 GW2 The following symbols are used LED off QO Flashing LED Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com LED constantly illuminated Remote Process Interface RPI System Error Messages LED red Communication LC Display LED red Internal communication Button ESC LED green Button Up ihn it Button OK LED yellow red Button Down External bus i isle w Pye RS 232 brows Rotary switch 3 5 mm Jack bush BA ewe termination resistor wo AP he for PROFIBUS Re abs iw Removable terminals Serviceinterface s geen SS gateways Copyright Pepperl
73. the external bus system Detailed information on the possible status of the LEDs on the front panels of the devices is pro vided in the appendix section 11 RPI System Error Messages Note Error Detection Using the LC Display on the Gateway An error code is displayed on the LC display on the gateway which can be used to diagnose the error A list of the error codes is given in Chapter in the appendix Kapitel 11 RPI System Error Messages Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 8 5 1 3 8 5 2 8 5 3 8 5 3 1 8 5 3 2 Remote Process Interface RPI in Operation Error Detection Using the PAC Tare Human Machine Interface Detailed information on the status of the RPI system can be obtained from the PACTware human machine interface Errors are indicated by coloured identification of the devices involved in the main menu The error can be precisely pinpointed using the diagnostic menu il Detailed information on error detection and diagnosis with the ie PACTware edition 2 human machine interface are given in Part PACT ware ote Error detection from the control system engineering console Depending on the type of implementation in the control system it is also
74. the project tree using the left mouse button and then press function key F5 Now the offline parameterization window opens displaying the tabs Device Info Description and Para meter 6 3 1 Parameters of the COM Drivers 6 3 1 1 RPI Serial Interface The lt Parameter gt tab is used to set the serial interface together with the port designation on your PC and the baud rate IP PACT ware lt COM1 gt RPI Serial Interface Parameter 8 x w Fie Edt View Device Ewas Windows Help 18 xi sga Wib EB E Serial Post Da cou HART Driver FOT Port com 7 eo ei acon KFNS Baudete 19200 WY lt COM1 gt API Seral Interface Ka lt 001 000 RSD2 GW PRO_485 a ge lt 003p KSD2 C1 5 EXH a lt 004 gt KSD2 B1 Exd g lt 005p KS02 00 5 EXH wd Mi p KSD2 B0 EX2 2 a my lt 007 gt KSD2 TI EX Figure 6 3 Parameterize the serial interface Serial interface Port Setting the designation of the serial port on the PC notebook Baud rate Must correspond to the set baud rate on the PC notebook 6 3 1 2 HART Protocol Driver The lt Parameter gt tab is used to set the serial interface together with the port designation on your PC the baud rate as well as a number of HART parameters Detailed information can be obtained from the HART Multiplexer KFD2 HMM 16 Handbook 18 x i E l x sga Whi tt ES HOST PC mm lt COM1 gt HART Driver FOT BART Communication interface HART multiplexer 7 re ALE EDA Serial ntetace Port
75. the settings that are made via the user parameters will apply to all RPI devices il of the gateway Note User parameter byte Value Meaning 00h oth 00h 07h 00h 01h automatic switch over to redundant gateway in the event of the active gateway becoming defective recommended for gateway with RPI inter nal address 2 02h redundant gateway waiting for switch over command 03h Switch over of the passive gateway into the active mode recommended for gateway with RPI internal address 2 xOh without status transmission xth with status transmission Oxh packing only possible using special IDs 1xh packing always possible Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 119 7 2 9 1 120 Remote Process Interface The setting of the data format for analogue values user parameter byte 2 and the transmission of status values via the data telegram both have an effect on the data volume to be transmitted and thus on the me mory space requirement and the cycle time O Independent of whether data transfer is carried out with or without status the PROFIBUS diag il nosis can be evaluated at any time Note More detailed information is given in section 7 2 9 3 Representation of the RPI modules in the Gateway The term module in
76. to 0 Modbus Plus supports the eight HOST commands listed below Further details can be found in the Modbus Plus Gateway User Manual e HOST command 1 Exchange data e HOST command 2 Set I O data structure e HOST command 3 Set redundancy mode e HOST command 4 Read module diagnosis e HOST command 5 Single channel function diagnostics e HOST command 6 Read error code and channel alarms e HOST command 7 Read gateway ID list e HOST command 8 Read RPI system module types Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 167 168 Remote Process Interface Read Holding Register registers 1 10 Register Byte Description of Read Holding Register Low Host Command Ack Register echo of the Host Command register to verify if this is the response to the latest High host command Response Counter Modbus Plus data register update in the RPI Gateway The RPI Modbus Plus may response to a single Host Command periodically The Response Counter is incremented by one for each response For each new Host Command the coun ter counts starting from 1 O High Low RPI Status Counter a counter for status change of the RPI A change in the counter indicates either an error status change in ERROR_CODE LIST
77. to 250 field devices sensors or actuators HAR T control module KFD2 HC HAR T devices HAR T multiplexer master Gateway type e g KSD2 Cl S Ex H KFD2 HMM 16 KSD2 GW Figure 3 3 HART multiplexer master and HART control module Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 26 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Product Description 3 1 7 3 HART Transmission via PROFIBUS The PROFIBUS DP V1 gateway KSD2 GW2 PRO has an integrated HART multiplexer system that offers full functionality The transmission of the HART protocol is carried out through PROFIBUS DP V1 or the RS485 service interface to the control system or a connected engineering console Within the RPI system the HART protocol is transferred via rail 4 of the Power Rail to the RPI devices up to 250 field devices sensors or actuators Gateway KSD2 GW2 PRO Service interface RS232 3 5 mm jack bush Service interlace A5485 PROFIBUS DP VI Figure 3 4 PROFIBUS DP V1 gateway KSD2 GW2 PRO Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Int
78. to carry out calculations self diagnoses and error reports Suitable RPI modules are available for the transmission of the HART protocol Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Product Description 3 1 7 1 HART Programming Unit With Direct Connection up to 250 field devices sensors or actuators HAR T devices e g KSD2 CO S Ex H ne Connector for programming device Figure 3 2 Connection of the HART programming unit to the terminals of the RPI device The RPI devices are equipped as standard with the appropriate terminals for the connection of the pro gramming unit The connection can be established on the safe side Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 25 Remote Process Interface Product Description 3 1 7 2 Transmission via HART Multiplexer The HART protocol is transferred by the KFD2 HMM 16 HART multiplexer master to the KSD2 HC HART control module and further on to the RPI module via rail 4 of the Power Rail up
79. you in planning the system and provides support for the docu mentation Having installed the RPI system it is configured using the push buttons and the LC display of the gateway The project data generated offline is transferred to the gateway in the next step These are the steps to be followed during commissioning 1 The RPI system should be installed according to the planning using the PAC Tyre edition 2 human ma chine interface on the PC The structure of the RPI system with the gateways the individual I O mo dules and the service interfaces has to be rebuilt accordingly and configured Parameters for the individual RPI modules are entered in register cards as shown in Chapter 6 Parameter Assign ment 2 If your RPI system is designed with gateway redundancy the redundant gateway is inserted in the structure of the RPI system just below the active gateway When parameterizing the gateways please make sure that the active gateway for the RPI internal bus has address 1 and that the redundant ga teway has address 2 Similarly the gateways receive different addresses for communication on the higher level fieldbus later on 3 Installation and connection of the RPI system as described in Chapter 4 11 Installation 4 Switching on the power supply for the RPI system as described in Chapter 5 2 Power Supply 5 The RPI modules are configured via the gateway see Chapter 5 4 Configuration Parameter Assignment 6 Fo
80. your RPI systems From the Control System Engineering Console Depending on the type of implementation in the control system the RPI can also be controlled from the con trol system engineering console Access is obtained for reading and writing to the complete data contents of all the connected gateways and RPI devices Measured values status values configuration data and pa rameters Error Handling When an error occurs a message is always generated by the RPI system If there is not an error on the gateway or if the system has a redundant gateway then the unaffected circuits continue to operate unin terrupted So far as is possible the faulty devices output replacement values to the control system and in the field Error Detection within the RPI System The RPI system offers a number of methods of error detection and device diagnosis There are four main procedures e Error detection using the LEDs on the devices e Error detection using the LC display on the gateway Error detection and device diagnosis using the PAC Tare human machine interface e Error detection and device diagnosis via the external bus Error Detection Using the LEDs on the Devices The LEDs on the front panels of the gateways and the RPI devices provide information on e Voltage supply e Lead breakage or short circuit of the field circuits e Device errors e Status of the internal communication via the bus e Status of the external communication via
81. 13 Setting the Transfer Rate for the RS 232 RS 485 Service Interface ParBaud Service Menu On selecting the ParBaud menu the currently set transfer rate is shown in the display The following trans fer rates can be set Transfer rate Display indication 1 2 kbit s 1200 Baud 2 4 kbit s 2400 Baud 4 8 kbit s 4800 Baud 9 6 kbit s 9600 Baud The transfer parameters for the RS232 RS485 service interface are fixed and cannot be changed e 1 Start bit e 8 Data bits e 1 Stop bit e Even parity O il Compare the transfer parameters with the values of your PC listed in the menu item System Control Note Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 87 9 4 3 14 9 4 3 15 9 4 3 16 9 4 3 17 9 4 3 18 88 Remote Process Interface Configuring and Commissioning the RPI System Setting the Gateway Address on the External Bus HstAdr Service Menu On selecting the Host Address menu the currently set gateway address on the higher level fieldbus is shown in the display It can be changed in a range of 0 126 Setting the HART Transmission HART Service Menu In this menu the parameters for the HART protocol transmission are set by means of the HART Multiplexer which is integrated in the gateway T
82. 2 Data byte 1 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 157 158 Remote Process Interface Writing reading analogue output data 2 channel devices All measured values from 1 and 2 channelled devices are represented in this area as a function of the cur rent RPI address The register addresses can be obtained from the following equations Data format Register address Signed integer 2 RPI address 3 376 Floating point 4 RPI address 3 626 2 registers have to be read written to in signed integer format in order to access the data from an RPI de vice The data is constructed as follows Register address 1 Register address Channel 2 Channel 1 In the floating point format 4 registers have to be read written to in order to access the data of an RPI de vice The data is constructed as follows Channel 1 Register address 1 Register address Channel 2 Register addresst3 Register address 2 Data byte 4 Data byte 3 Data byte 2 Data byte 1 Data for unoccupied channels is set to 0 Reading status information The status information is filed in separate registers One RPI is always allocated to one register and can have up to 2 channels The register address can be obtained as follows Register addr
83. 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 177 8 4 8 4 1 8 4 2 8 4 3 8 4 4 8 5 8 5 1 8 5 1 1 8 5 1 2 178 Remote Process Interface RPI in Operation Servicing and Diagnostic System The components of the RPI system do not require servicing within the given environmental conditions Fault conditions on the gateways and devices are indicated by the diagnostics of the RPI human machine inter face Via LEDs LCD and Pushbuttons on the Devices The failure of devices is indicated via the LEDs on the devices and the LC display on the gateway see Ka pitel 5 Configuring and Commissioning the RPI System Via PC and PACTzare or RPI Human Machine Interface If a PC is connected to the RS 232 RS 485 service interface of the gateway extensive diagnosis can be retrieved via the PACT ware edition 2 human machine interface In this event the faulty device is indicated in red on the PC If the device concerned is marked with the cursor all the relevant data on the RPI modules can be requested via the Diagnosis menu The same messages are also available on the control system via the external bus Via a Permanently Installed PC Based Service Level If gateways are used with the RS 485 service interface the gateway service interfaces with up to 31 RPI segments can be networked with a common PC Thus the RPI human machine interface provides the function of a central engineering console for
84. 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com The entered address must be identical with the address set on the relevant device It allows you to type in a descriptor tag name which may contain up to 32 characters This is helpful for larger projects to identify the devices clearly The sensor lead is monitored for lead breakage The sensor lead is monitored for short circuits The input signal is inverted and transferred to the bus By means of the settings Downscaled Upscaled or Hold Last Value the signal transferred to the control system in the error case is determined according to the application Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Parameter Assignment 6 3 6 Relay Modules The Parameter tab contains both device specific and channel specific parameters 5 x lt 003 gt KSD2 RO EX2 Parameter i Device address Address E Channel 1 Channel 2 L SS y Tag name Output Invert signal Mal function output status logic zero X Help Figure 6 12 Parameterizing KSD2 RO Device Address The entered address must be identical with the address set on the relevant device Tag Data Tag Name It allows you to type in a descriptor tag name which may contain up to 32 characters This is helpful for larger projects to identify the devices clearly
85. 5 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 9 4 2 6 9 4 2 7 Remote Process Interface Configuring and Commissioning the RPI System Setting the Transfer Rate of the RS232 RS 485 Service Interface On selecting the operating mode G BAUD PAR the currently set transfer rate is shown in the display The transfer rate for the RS 232 RS 485 service interface can be set by means of the W and A pushbuttons The set transfer rate is accepted by depressing the mode button for longer than 3 s The following transfer rates can be set Transfer rate Display indication 1 2 kbit s 2 4 kbit s 4 8 kbit s 9 6 kbit s 33 6 kbit s 38 4 kbit s 57 6 kbit s The transfer parameters for the RS 232 RS 485 service interface are fixed and cannot be changed e 1 Start bit e 8 Data bits e 1 Stop bit e Even parity 1 O il Compare the transfer parameters with the values of your PC indicated in the menu item sys i tem control ote Setting the Transfer Rate of the External MODBUS On selecting the operating mode H BAUD EXT only available on MODBUS gateway the currently set transfer rate is shown in the display The MODBUS transfer rate can be set by means of the 4X and but tons The set transfer rate is accepted by depressing the mode button for longer than 3 s The following transfer rates can be set Transfer rate Display indication 1 2 kbit s 0
86. 55 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface 7 2 10 Commissioning Before commissioning an additional check should be made that all connections are correct Personnel undertaking commissioning should be familiar with communication between the PROFIBUS ma ster and the gateway Commissioning requires knowledge of PROFIBUS DP and how to configure and pa rameterize the master device Time response The Remote Process Interface is deterministic The RPI devices are interrogated cyclically The most important factors affecting the time response are The higher level host system e g process control system PLC or PC Type and number of PROFIBUS masters e g specified transmission rate Type and number of PROFIBUS slaves e g when using several gateways Communication between PROFIBUS master and host system Number of RPI devices and cycle time of RPI system see Chapter 4 Planning Basics and Procedure The user program O Further information about commissioning is provided in Part System Description Planning il Installation Commissioning and Servicing Important information about commissioning will also be found in the technical documentation for the DP master system Note There is a whole range of project tools available that enable the PROFIBUS user to plan and commission a network without in depth knowledge of the bas
87. 65 67799091 Internet http www pepperl fuchs com 173 Remote Process Interface RPI in Operation MONITORING SIMULATING MEASURED VALUES AND ERROR HANDLING 8 RPI in Operation By monitoring and simulating process data as explained below the RPI system and the connected control system can be checked prior to commissioning While the system is in operation measured values can be monitored over a lengthy period of time and trend analyses can be made Just open the respective window on the PACTware human machine interface by clicking onto the required device with the right mouse but ton 8 1 Displaying Measured Values The Measured Value window shows the current input values in the binary or analogue format Binary si gnals are displayed in the form of LEDs while analogue input signals are displayed by means of a scaled bar graph The scaling of the display corresponds to the parameterization of the channel lt 007 gt KSD2 TI EX Monitor oO 10 x Kanal 1 PLT Stelle Figure 8 1 Window displaying analogue values O il To enable the data of selected devices to be read out and any changes to be indicated it is necessary to mark the check box Check connection to RPI device cyclic Note Channel Tag name State 1 G 2 G S G A D G EEELEFEEETETETEENEETETEEEETTTTETTETETTTTTET Figure 8 2 Window displaying binary inputs Subject to reasonable modifications due to technical advances Copyright
88. 67799091 Internet http Awww pepperl fuchs com 67 Remote Process Interface Configuring and Commissioning the RPI System Power Rail supply module and bus 2 recesses Figure 5 2 Setting the mode of operation of the relay Jumper between Mode of operation of the relay 1 and Normally open 1 and Il Normally closed The mode of operation is set to normally open in the setting on delivery Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 68 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Configuring and Commissioning the RPI System 5 3 RPI Devices 5 3 1 Construction of the RPI Devices Removable terminals blue LED green LED yellow red i sania Power suppl Input check channel II 4 5 7 F Sia LED red LED yellow red a Fault signal Input check channel I _ 1 3PWR LED yellow red __ OE Input check channel II LED yellow red Input check channel IV Figure 5 3 Front view of RPI device O The RPI system devices have 1 2 or 4input and output channels depending on the model The il construction the operation of the devices by means of the ADR button address and the LEDs are identical for all models Note An IN CHK and OUT CHK LED is available for each indivi
89. 7799091 Internet http Awww pepperl fuchs com 151 152 Remote Process Interface O If your control system does not support access to the input registers Table 04 the register addresses can be obtained from Chapter 7 3 13 Note Writing reading analogue output data 1 channel devices This data is deposited in register table 3 which can be read via the function code 03 and written to via function code 05 Preset Single Register and function code 16 Preset Multiple Register The register address is dependent on the RPI internal address It can be derived from the following equati ons Data format Register address Signed integer RPI address 4608 Floating point 2 RPI address 3 6150 In the signed integer format only 1 register must be read and written to In the floating point format 2 registers have to be read written in order to access the data from an RPI de vice The floating point format data is structured as follows Register address 1 Register address Data byte 4 Data byte 3 Data byte 2 Data byte 1 Writing reading analogue output data 2 channel devices All the measured values from 1 and 2 channelled devices are represented in this area as a function of the current RPI address The register addresses can be obtained from the following equations Data format Register address Signed integer 2 RPI address 3 5126 Floating point 4 RPI address 3 7052 In the signed integer format 2
90. 9 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com Copyright Pepperl Fuchs Printed in Germany 125 126 Remote Process Interface If the transfer with status byte option is selected the status byte is structured as follows Good OOOO ee oa Not certain Ci et oo ee eee coan fo fo fo Measurement range God 00 eet eae saor Smulteameasweavas lij o i oli x Rema ooo o o aa CDs 7 XK Corgwaionrr lo o i il olx Reaver o o ox Fielddeviceeror lil lo o il olx No communication lastgoodvaluey 1 0 1 1 0 x Nolimitvaue reached olol x Lowerlimitvilated oo a y o XC Upperlimitviolted o l I x For binary inputs and outputs the Dat bit O represents the current status of the channel For analogue in puts and outputs it is always set to 0 Q1 and Q2 provide information on the signal quality If an error occurs this bit is always logical 1 CD1 to CD3 code any errors which have occurred In the event of a field device error no distinction is made between lead breakage lead short circuit or a defective field device Bits GW1 and GW2 are reserved for monitoring the limit values of analogue inputs and outputs They are insignificant for binary signals Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 42535
91. Address F Channel 1 r Tag data Tag name Senso i Sensortype Ohm Linear Limeanta Unit E Ohm n Wining 2 wire x 2 wire Calibration a Notch Teguency oa fie breakage detection Short creut detection Limit TT Warming limits active mi Alame limits active Limits of measuring range Lower oo Ohm Upper Output Mal function Maximum va output status The entered address must be identical with the address set on the relevant device It allows you to type in a descriptor tag name which may contain up to 32 characters This is helpful for larger projects to identify the devices clearly In this menu you can select a sensor from a list of various sensor types The connection method of the sensor to the RPI module should be set using this list box In this box the input signal can be assigned a physical unit Here you can enter values into a table Ohm Temperature The sensor lead is monitored for lead breakage The sensor lead is monitored for short circuits If you check the left box by clicking into it you activate the warning limits Now Lower Limit and Upper Limit turn from grey to black The limit values are entered into the boxes on the right hand side If you check the left box by clicking into it you activate the alarm limits Now Lower Limit Upper Limit and Hysteresis turn from grey to black The limit values are entered into the bo xes on the right hand s
92. Address fo He hp Close Figure 6 7 Parameterizing the PROFIBUS DP gateway The Password Panel tab enables you to lock the operating unit and to activate the passwords by checking the respective boxes il The device address 127 is reserved for a specific PROFIBUS service and cannot be set on the gateways Note 6 3 2 4 ControlNet The tab for the gateway parameters contains the tabs Communication and Password Panel Two pa rameters have to be set for the communication of the gateway e Address on the ControlNet bus 0 127 e Address of the parameterization interface 0 127 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 e USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 99 Remote Process Interface Parameter Assignment The section Internal Communication indicates the Operating Mode and the Internal Cycle Time However they cannot be changed a lt 001 000 gt KSD2 GW CN Parameter Communication Password display M Internal communication Operaton mode Master gateway device address 1 Internal cycletime ooo ms CN Parameter Adresse h n lt 001 000 gt KSD2 GW CN Parameter Communication f Password diena Display Panel locked r RT Password 1 PE FU Password aktive 6 3 3 100 Password 2 PEFU Param
93. Connection to the RPI internal bus and to the supply voltage is achieved automatically when the devices are snapped onto the mounting rail Power Rail assembly The intrinsically safe signal circuits are connected to the blue terminals of the RPI devices in accordance with the applicable regulations and directives O The connection diagrams and terminal allocation lists for the devices are given in the data il sheets Note Special instructions for the connection of the external bus system as for example recommen ded bus cables permissible cable lengths fieldbus terminators etc are given in Chapter 7 Integration into the Higher Level Bus System Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 65 5 1 66 Remote Process Interface Configuring and Commissioning the RPI System Configuring and Commissioning the RPI System Offline Commissioning Offline commissioning enables you to document and largely prepare the RPI system for actual commission ing on your PC during the planning phase The RPI system can be configured and the topology can be designed accordingly using the PAC Tare hu man machine interface Configuration and parameter assignment can be largely carried out without the RPI system This kind of commissioning assists
94. Ex H 1 channel HART Transmitter Power Supply with Ex approval SMART via terminals HART via Power Rail and terminals e KSD2 CI S H 1 channel HART Transmitter Power Supply SMART via terminals HART via Power Rail and terminals 3 3 6 Analogue Driver Repeater e KSD2 CO Ex 1 channel Analogue Driver Repeater with Ex approval e KSD2 CO 1 channel Analogue Driver Repeater e KSD2 CO S Ex 1 channel SMART Analogue Driver Repeater with Ex approval e KSD2 CO S 1 channel SMART Analogue Driver Repeater e KSD2 CO S Ex H 1 channel HART Analogue Driver Repeater with Ex approval SMART via terminals HART via Power Rail or terminals e KSD2 CO S H 1 channel HART Analogue Driver Repeater SMART via terminals HART via Power Rail or terminals Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Remote Process Interface Product Description Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 31 3 3 7 3 3 8 3 3 9 3 3 10 3 3 11 32 Remote Process Interface Product Description Current Frequency Converters Batch Controllers Flow Meters e KSD2 Fl Ex e KSD2 Fl 1 channel Current Frequency Converter with Ex approval for the connection of proximity switches and digital sensing elements e g optical or mechanical 1 channel Current Frequency Converter for the connection of proximity switches and digital sen
95. Fuchs Printed in Germany 193 194 Remote Process Interface RPI System Error Messages No voltage supply m CO E 3 O 07 2 A Q a D D 2 Voltage supply present OC O Indication of the gateway address for the RPI internal bus O O O LED INT red Internal bus in normal operation Internal bus or device error Internal interface error 2 O 2 O O erh LED EXT yellow red Yellow LED external bus in normal operation Red LED no communication on external bus One EXT Red LED internal interface error Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface RPI System Error Messages LED COM red QO Normal condition internal CAN bus in differential mode Cre OO O Internal CAN bus in common mode redundancy failure OO COM RAM ROM EEPROM error or other internal error O O RAM ROM error or other error red EXT LED lights Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 195 Remote Process
96. Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Glossary PC Personal Computer PHY Physical Layer DCS Distributed Control System PWR Power RAM Random Access Memory ROM Read Only Memory RPI Remote Process Interface SAP Service Access Point SCADA Supervisory Control and Data Acquisition SMART Self Monitoring Analysis and Reporting Technology PLC Programmable Logic Controller Tag Number Measuring point description USV Unterbrechungsfreie Stromversorgung UPS Uninterruptible Power Supply Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 217 Worldwide Headquarters Pepperl Fuchs GmbH 68307 Mannheim Germany Tel 49 621 776 0 E mail info de pepperl fuchs com For the Pepperl Fuchs representative closest to you check www pepperl fuchs com pfcontact www pepperl fuchs com Subject to modifications Copyright PEPPERL FUCHS Printed in Germany _ FJ PEPPERL FUCHS PROTECTING YOUR PROCESS 043014 TDOCT 0129B 03 2005
97. H lt 002 1 KSD GW PRO La List of possibilities Set the structure of a project The three parts of the edit window PROJECT LEFT This part of the window shows you the present project as is You can select items that should be copied into the clipboard or removed from the project and you can also configure the selected item Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface K SK1 CLIPBOARD RIGHT The clipboard has three different views The copy view the project view and the device list view The copy view is suitable if you have to copy parts of your project Instead of adding piece by piece to your project you copy the part into the clipboard and add it to the project again as often as you want This method works for single items as well as for whole branches or trees The project view opens a former project and you can copy the whole project into your current one or any part you like If you want to change the content of this view select Clipboard Open Project The device list offers you a complete list of devices you may add to your project The content is depending on the selected item and gi
98. IC VERSION Figure 3 5 PAC Tare the human machine interface for the Remote Process Interface Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 e USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 33 3 9 34 Remote Process Interface Product Description Control Cabinets Assembly and Service Pepperl Fuchs offers fully assembled and tested control cabinet systems They are equipped with RPI de vices according to customer requirements and based on measurement and automatic control engineering Local Pepperl Fuchs sales offices will be pleased to advise on alternative installations and the most suitab le control cabinet layout for a given application The following diagram shows a possible arrangement of an RPI system in a control cabinet Detailed view Carrying plate Door Power supply units a E E as H fl i e Lo t E BDN cl oe Y o os LY N E N E N E T 7 D O O i t Ta i Th H Door i i t t l L Li 1 i ft __ _ a 1 y 1 ft a T lid DU o Y E F 7 1 KS module m 2 Wiring comb for direct wiring m ER j to the KS modules f i i 3 Comb cap o m i m 4 KF profile i e TS 5
99. Interface RPI System Error Messages 11 4 Error Messages on the RPI Devices via LED Removable terminals blue LED yellow red 1 2 3 Power suppl Input check channel IH 4 5 6 g KSD2 H N fa Fault signal LED yellow red N Input check channel _ b 3 PWR LED yellow red wee Input check channel I LED yellow red Input check channel IV Figure 11 2 Front view of RPI device O The RPI system devices are provided with 1 2 or 4 input and output channels depending on the Il model The construction the operation of the devices with the ADR button address and the LED display is identical for all types Note A IN CHK or OUT CHK control LED is available for each individual channel The following symbols are used LED off Flashing LED LED constantly illuminated Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 196 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface RPI System Error Messages PWR Ore No voltage supply Ore OO O Voltage supply present Setting and checking the device address OO No error OO ERR Cue O Bus error kd O Q EELE Oe Hardware error specification via IN CHK or OUT CHK LEDs ERR IN CHK or OUT CHK LED s 1 4 OO Input output channel 1
100. Internet http www pepperl fuchs com 201 12 3 3 3 12 3 3 4 12 3 4 12 3 4 1 202 Remote Process Interface K SK1 Opening an existing project Select Project Open to load an existing project into the project manager If you have another project open that contains changes you want to keep use Project Save or Project Save as first Saving a project To save a project select Project Save or Project Save as The latter let s you change the name of the project if you do not want to overwrite an existing project with the changes made A valid name contains up to 8 characters and the extension prj If you do not need to add the extension In this case K SK1 will add the extension automatically If you save a project for the first time it s always saving as Editing a project To edit a project select Project Edit from the menu and the edit window appears You have full control over the project tree in this window You can add or delete devices or whole branches and it also lets you configure the basic information like the slave address or tag name of each device O The order of the devices in the tree does not have to be identical with the order in the cabinet il The devices are addressed by their slave address not by their physical order Therefore it is not important where they are located in the device tree However the device tree is sorted by slave address F Pepperl Fuchs K 5K 1 Edit Project O
101. KSD2 GW2 LED red Communication LED red LED red Communication Internal communication A NORM b a eT LED red _ a ee d ADR EXT Internal communication D yellow red gt j s F sauD nT i Button Up LED green External bus B BALO PAR opia supply Button Down LED yellow red Mode button Rotary switch termination resistor for PROFIBUS RS 232 3 5 mm Jack bush Removable terminals green Figure 5 5 Front view of KSD2 GW and KSD2 GW2 gateway External bus AS 232 3 5 mm Jack bush RS 485 Serviceintenface The following symbols are used in the descriptions below LED off i Flashing LED LED constantly illuminated Subject to reasonable modifications due to technical advances 72 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Rotary switch termination resistor for PROFIBUS Removable terminals green Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Configuring and Commissioning the RPI System rr m g z A D D PWR No voltage supply Ore CO PWR Voltage supply present O ore PWR Display of the gateway address for the RPI internal bus O ore LED INT red Internal bus in normal operation Internal bus or device error 2 O One Internal interfa
102. LUICHS GmbH RPI mie KSD2 BI EX PEPPERL FUCHS GmbH RFI ais KS0 2 BO EX FEPPERL FUCHS GmbH RFI aby KS02 60 EX2 2 PEPPERL FUICHS GmbH RPI me kabi PEPPERL FUCHS GmbH RPI BAKSO 2 CLEX2 PEPPERL FUCHS GmbH RPI am KS02 C1 5 PEPPERL FUCHS GmbH RPI me KSD2 Cl 5 H PEPPERL FUCHS GmbH AFI ae KS02 015 Ex PEPPERL FUCHS GmbH RFI Aa kS02 C 5 XH PEPPERL FUCHS GmbH RFI eakso2 C0 PEPPERL FUCHS GmbH RPI aoe SD 2 CO EX PEPPERL FUCHS GmbH RPI A KSD2 CO EX 741170 PEPPERL FUCHS GmbH RFI im KSD2 C0 5 PEPPERL FUICHS GmbH RPI ee ee Se renee H Br Pet RI JPM be mah Gey x je RL FUICHS GmbH OTM Component s Posen pierre tranemilter a kaps E Init device catalogue Ho ae fe RPimanuaiPy E mi Astart 7 GS Kander Microso 2A Venus Ef windows Comman 1PACTware D 7 Unbenannt Paint B24 1248 Figure 6 2 Device catalogue O Make sure to activate i e highlight grey blue exactly that level in the left column which can be used to project your component Note This means that if you wish to project a COM driver the HOST IBM PC must be activated Similarly if you wish to project an RPI device an RPI gateway should be activated If this is not the case an error message appears PACTware M adds a device and assigns this device an address for the RPI internal bus simultaneously The first gateway is generally assigned Number 1 the second gateway Number 2 and the first RPI device is assigned Number 3 A gateway can communicate w
103. ONFIGURING AND COMMISSIONING THE RPI SYSTEM cccccsccecccececceccescncccccsncncccensnenesesess Ofline COMMISSIONING vad ctecccesesceasadaescecncanenenaacntsncucneanscounadeencsanatsunsievsedosahexsiemsavewencnacisucusesdisunsiceressascen POWER SUDO IY sonia cance eeecatene ne encensosaeteesswsesdedeacteucas weds tacteeoseueeace E E Construction of the Power Feed Module cccceccceseeen ect eeee en eceeseee ence eeeeaeeaeeeaeecesaeeaseceeneeanetseseeaeateneeaees Setting the Mode of Operation of the Relay cccccccesececeasenececeaeececeaeaeeeeeeaeeaeeeeeaeeeeaeaneseeeaneeeseasaneeeees IO VICES aiinne rinena teyhantas ueinauessonaneenuniibsiacmatuentel Construccion OF Tile RPILDEVCES a caeaecesstatencastecaatencosusnraeae ca teaancecanesuacania auncaniseeatecaaeersaadecauiperiaceurtsoimeeunteen LEDs on the Front Panel ofa D VICE 0 0 ceccece cece cece seen eeeceeetee ence eeteseeaneeteseesaeeaeseeaaeeaeeateneeaeeasesteaeeanesteas COnN OU HON 5s cece coco a ence es cnc eee conde ectea cece ce cabana a E E A Copyright Pepperl Fuchs Printed in Germany 5 4 1 5 4 2 5 4 2 1 5 4 2 2 5 4 2 3 5 4 2 4 5 4 2 5 5 4 2 6 5 4 2 7 5 4 2 8 5 4 2 9 5 4 2 10 5 4 3 5 4 3 1 5 4 3 2 5 4 3 3 5 4 3 4 5 4 3 5 5 4 3 6 5 4 3 7 5 4 3 8 5 4 3 9 5 4 3 10 5 4 3 11 5 4 3 12 5 4 3 13 5 4 3 14 5 4 3 15 5 4 3 16 5 4 3 17 5 4 3 18 5 5 5 9 1 5 5 1 1 9 0 1 2 5 5 2 5 5 2 1 5 5 2 2 5 5 3 5 6 5 6 1 5 6 2 5 6 2 1
104. Output Invert Signal The input signal is inverted and transferred to the bus Malfunction Output Status By means of the settings Downscaled Upscaled or Hold Last Value the signal transferred to the control system in the error case is determined according to the application 6 3 7 Transmitter Power Supplies The Parameter tab contains both device specific and channel specific parameters aad lt 003 gt KSD2 Cl S EX H Parameter lol x Gerateadtes_ Adresse 3 7 Kanal 1 MeBstellendaten MeBstellenbezeichnung Einheit m Strombereich 4 20m4 gt Leitungsunterbrechung melden Leitungskureschluss melden Grenzwerte T Wamorenzen aktiv Untere Grenze fo 0 m Obere Grenze fo 0 m Ubere Grenze fo 0 m Hysterese fo l m Messbereich Anfang 4 0 m Ende 20 0 m _ Ausgang Ausgangszustand bei Fehler Alatmarenzen aktiv Untere Grenze 0 0 m Figure 6 13 Parameterizing KSD2 CI Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 103 104 Device Address Tag Data Tag Name Sensor Unit Current Range Lead breakage detection Short circuit detection Limit Values Warning limits active Alarm Limits active Measurement Range
105. PACT ware edition 2 is directly connected to the gateway and that the devices can be parameterized on site For this kind of commissioning a distinction must be made between two different situations Fully Mounted RPI system For a fully mounted and configured RPI system the configuration can be uploaded on the PC as described in Chapter 5 6 2 The parameter assignment is carried out according to Chapter 6 Parameter Assign ment and is downloaded to the RPI device in question Successive Assembly of the RPI Devices The Power Rail power supply and gateways are mounted and the unconnected terminals of the RPI de vices and the sensor and actuator cables are screwed together This situation may arise when KFDO LGH dummy housings were originally installed which are later on replaced by RPI devices Commissioning takes place analogous with Chapter 5 6 1 however no preplanned PACTyare project is downloaded to the gateway After an RPI device has been snapped on it is automatically assigned the next free address by the gateway The parameter assignment for this device can now be carried out After that the next device can be snapped onto the Power Rail if required Configuration and Parameter Assignment via PROFIBUS DP V1 This method of configuration and parameter assignment can only be carried out using the KSD2 GW2 PRO Gateway for PROFIBUS DP V1 in conjunction with PAC Tare Edition 2 or with another FDT compatible human machine
106. PF0818 GSD GSD file and these are addressed by the DP master device using a common address O To allow the gateway s automatic DP slave module address assignment function to continue to il operate in this case the devices included in a DP slave module must have consecutive RPI addresses Note The sum of all the identifiers in a configuration must not exceed 244 bytes This is a PROFIBUS constraint O If the limit of 244 bytes for the sum of all identifiers in a configuration is approached module types that will support a number of RPI devices per module should be used as much as pos sible Note Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 7 2 9 2 Remote Process Interface RPI Bus Address DP Slave Module Address i 11 2 pe 79 4 42 J 43 When configuring a PROFIBUS DP system each module must be assigned a module type The available module types are defined in the device master data file Data Structure on the PROFIBUS Each device inserted into the DP slave window is automatically assigned an address range The assign ment of peripheral addresses to the RPI devices or to the individual DP slave modules is carried out auto matically via the PLC or the host comput
107. PI devices Depending on the device type different tabs are opened in order to be able to parameterize the de vices Detailed information is given in appendix B about PACT ware Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Quick instructions 11 Store the project Save the data for your RPI system on your PC by selecting Project Save as You can select any name for your project but the file extension is always PW 12 The configuration of the RPI system is now complete You will next install the gateway and download the configuration into the hardware 13 Installation of the gateway Snap the gateway onto the mounting rail containing the Power Rail The green PWR LED indicates that the power supply is present The COM Communication EXT External and INT Internal ga teway LEDs flash The gateway version number appears briefly on the display followed by SYN Syn chronisation 14 Cable connection Now connect the gateway parameterizing interface with your PC interface using the cable supplied If you are using a gateway with an RS232 parameterising interface connect your PC either to the jack on the front or to the plug
108. PROCESS AUTOMATION D REMOTE PROCESS INTERFACE FJ PEPPERL FUCHS PROTECTING YOUR PROCESS REMOTE PROCESS INTERFACE With regard to the supply of products the current issue of the following document is ap plicable The General Terms of Delivery for Products and Services of the Electrical In dustry published by the Central Association of the Electrical Industry Zentralverband Elektrotechnik und Elektroindustrie ZVEI e V in its most recent version as well as the supplementary clause Expanded reservation of proprietorship FJ PEPPERL FUCHS Date of issue 06 03 03 1 1 1 2 1 3 1 4 1 5 2 1 2 1 1 2 1 2 2 2 2 3 2 4 2 9 2 6 2 7 3 1 3 1 1 3 1 2 3 1 3 3 1 4 3 1 5 3 1 6 3 1 7 3 1 7 1 3 1 7 2 3 1 7 3 3 2 3 2 1 3 2 2 3 2 3 3 2 4 3 2 5 3 2 6 3 3 3 3 1 3 3 2 3 3 3 3 3 4 3 3 5 RPI System Manual Table of contents INTRODUCTION SYSTEM DESCRIPTION AND RPI SYSTEM COMPONENTS THE REMOTE PROCESS INTERFACE RPI IN BRIEF csscesccnscesseeeseeeseeeseesseesennscessenesonsens Availability Functional Integrity and Function Monitoring cccececeeeeeeeneeeneeeseeeeeeneeaeaeeeeeneesenenanaas Aim Ofthe HandDOOK iriure a a eae Not s on Using the Handbook seivncecaccntecesrescencce canecennercudanaysiscseaudsanneaneketeuacautesceamasaadesereccbeeceutaonerseinemcenete Prerequisites for RPI System Operation sssnssnsnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnn nunne nnmn nnn nn n
109. Pepperl Fuchs K 5K 1 TEST PRJ Project Connection Ciola Diagnostic Device Data Options Exit Help Fe Devices Fo Nowa _ F4 Diagnostic ae E 4 Budding 1 analog valve 11 KSD2 C0 5 Ex 99 3 KSDI CI S Fx C 6 MeBstelle 2 KSD2 TI Ex 7 8 MeBctelle 12 KSD2 BO Ex C 13 KSD2 BI Ex4 Closing down the communication between K SK 1 and RPI Select the gateway in the project manager then Connection Go Off Line to shut down the commu nication The communication is also shut down if you select Project Edit during operation After the connection is shut down the devices in the project manager are displayed in normal letters again Editing Device Data There are two ways of editing device data online and offline In the first case you load and save the data directly from and to the device with a possibilty to save it to a file too in the second case you load and save the data from and to a file on your computer K SK also allows you to load the data from a device and save it to a file or vice versa The difference between both methods is the updating of the project The project is automatically updated if you save changes to the device If you save information only to files you have to update the project by down loading the new information with Project download In this case the project uses all data files extension dat related with that project to rewrite the device information O If you close the window containi
110. Pepperl Fuchs Printed in Germany 174 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface RPI in Operation 8 2 Displaying Trends The Trend window contains a recorder which displays the monitored values in a graph Analogue values are displayed according to the scale Y axis The two states of binary information are displayed as 0 value equals 0 and as 50 value equals 1 The lt Trend gt tab contains the sections Display and Trend On opening the Trend menu a recorder appears in the Trend section which displays the measured values continuously The time axis and the axis for the measured value may be adapted to suit the requirements by changing the scale range and the graduation of the scale Just move the cursor along the required sca le Hold the right mouse button depressed to scale the axis to the right and upwards and hold the left button depressed to scale it to the left or downwards The arrow button down on the right in the same section enables you to shift between updating and locking the display 7 lt 003 gt KSD2 Cl S EX H Trend 1o x E Channel 1 signal a IY Channel 1 short circuit 4 Channel 1 lead breakage w Channel 1 Low Singal War Sal Channel 1 High Signal Wat C Channel 1 Low Signal Alar 2 C Chann
111. R Hkr a AB T E AE pale EE ES oS e e 4 EJ 2 s gt ye ep Beige Be ee Gd ee 7 a ar Sei kiani ae a Figure 2 1 RPI system structure Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Safety Structure and configuration of the RPI system The system see figure 2 1 consists of the following components Model number Description KSD2 GW MOD 485 MODBUS Gateway KSD2 GW MOD KFD2 EB MAR RPI Power Feed Module 3 KSD2 BO Ex2 2 Solenoid Driver KSD2 BO Ex KSD2 TI Ex Converter KSD2 VI KSD2 MVI KSD2 Cl S Ex H HART Transmitter Power Supply KSD2 BI Ex4 Isolated Switch Amplifier KSD2 BI Ex2 KSD2 Fl Ex Current Frequency Converter E KSD2 CO S Ex H HART Analogue Driver Repeater KSD2 CO Ex KSD2 CO S Ex KSD2 RO Ex2 Relay Module KSD2 CI Ex2 Transmitter Power Supply KSD2 CI S Ex KSD2 PT2 Ex1 Potentiometer Input 2 5 Overvoltage and Lightning Protection While planning the RPI system the prevailing conditions in the field have to be tested in order to determine whether an overvoltage or lightning protection is required If it is required it has to be carried out in accor dance with the relevant literatu
112. Rate The PROFIBUS gateway synchronises itself with the transmission rate of the PROFIBUS master The following transmission rates are supported e 9 6 kbit s e 19 2 kbit s e 93 75 kbit s e 187 5 kbit s e 500 kbit s e 1 500 kbit s Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface O The transmission rate depends on the length and type of the cable used Detailed information il can be obtained from the PROFIBUS specification EM 50170 2 Note Bus termination With PROFIBUS each bus segment must be terminated at both ends with terminating resistors Bus termination 1 active Rotary switch S1 for bus termination on the Bus termination 0 right side of the device not active Actuating by means S1 of a screw driver Figure 7 5 Rotary switch S1 for bus termination The PROFIBUS gateways incorporate a switchable internal bus termination Using a screwdriver the bus termination can be activated on the rotary switch S1 on the right side of the housing as viewed from the front This is used if the gateway is installed at the end of a line 7 2 7 Screening and EMC The screening of cables provides protection against electromagnetic interference and increas
113. S sosnssonnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nenn nnnn nanne nnmnnn nnmnnn ISOLATED SWITCH AMPLIFIERS sssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnna nn nanne nnman nenne nn nnmnnn nanne nnmnnn ennan nnn SOLENOID DRIVERS AND RELAY MODULES wasecececnecnnecnncncncnncuncnsnsenseunsensennsennsnesennsensnenseceseeseensecunsnsneneananseans TRANSMITTER POWER SUPPLIES cise cnsccsczcseveeniestvacendwcsavcdivessisnnesvnsesevnsvonensncesemsesedebuenesucenwanisousheernsenteewseseenses Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 13 14 14 16 16 17 18 18 18 18 19 19 20 21 21 22 23 23 23 24 Communication Between the RPI Modules 00 0 0 cc ccc ccceccccecececcecececeeaeeecueuneeeneneneueeeeeceeaeaeauuaneneneneneeneneners 24 Sega 24 wares 24 25 26 27 28 28 29 29 na 29 11122130 30 31 31 31 31 31 31 3 3 6 3 3 7 3 3 8 3 3 9 3 3 10 3 3 11 3 4 3 4 1 3 4 2 3 4 3 3 5 4 1 4 1 1 4 1 2 4 1 3 4 1 4 4 1 5 4 1 5 1 4 1 5 2 4 1 5 3 4 1 5 4 4 1 5 5 4 1 6 4 1 7 4 1 8 4 1 9 4 2 4 2 1 4 2 2 4 2 3 4 2 3 1 4 2 3 2 4 3 4 4 4 5 4 5 1 4 5 2 4 5 2 1 4 5 2 2 4 5 2 3 4 5 3 4 RPI System Manual Tab
114. Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface 1 22 Gateway KSD GW2 PRO The KSD2 GW2 PRO gateway supports the cyclic and acyclic PROFIBUS DP V1 data protocol and has both serial service interfaces RS232 and RS485 The controls consist of a two lined alphanumeric LC dis play with 4 digits and the four buttons OK ESC Up and Down LED red Communication LC Display LED red p Internal communication Button ESC LED green Button Up Power supply Button OK LED yellow red External bus _ Button Down RS 232 Rotary switch 3 5 mm Jack bush termination resistor for PROFIBUS RS 485 Removable terminals Serviceinterface green Figure 7 4 KSD2 GW2 PRO gateway 7 2 3 General Notes on PROFIBUS DP PROFIBUS DP distributed peripherals is a standardised field bus that allows the rapid exchange of data between central automation devices and distributed field devices such as sensors and actuators Meanw hile the cyclic data exchange to DIN 50170 has been supplemented by PROFIBUS DP V1 which is also referred to as acyclic data data traffic O Further information can be found in the PROFIBUS standard EN 50170 DIN 19245 and the il releva
115. System Commissioning of the RPI system is carried out in three steps 1 Configuration 2 Parameter assignment 3 Integration into the higher level bus system The RPI system can be configured via the RS 232 or RS 485 service interface of the RPI gateway and each channel of each RPI device can be parameterized individually For simple and rapid commissioning Pepperl Fuchs offers thePACT are software package PACTware Process Automation Configuration Tool is an open source software with open FDT interface Field Device Tool which facilitates the multi vendor and uniform configuration of modern field devices Detailed infor mation on PACTware is given in Chapter 4 8 3 PACTware Configuration eAddress assignment of the RPI gateway on the higher level bus eAddress assignment of the RPI modules on the in system bus Definition of the communication with the higher level bus Definition of the communication via the RPI service interface Adjustment of the redundancy mode Usually the configuration is carried out via the operator level of the gateway Parameter Assignment Simulation of the structure of the RPI system in the commissioning software eAdjustment of the individual RPI modules to the requirements of sensors actuators and field devices Integration into the Higher Level Bus System eis described depending on the bus system used in the respective chapters of this handbook PACT ware EDITION 2 BAS
116. System Channel 1 Short Circuit Lead Breakage Low Singal Warning High Signal Warning Low Signal Alarm High Signal Alarm Signal under Measuring Range Signal over Measuring Range I7 cyclic refresh diagnosis Help Sse Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 57 Remote Process Interface Planning of the RPI System 4 8 4 Interface adapter for RS 232 and RS 485 Connection of a PC or Notebook to the RPI service interface using the PACTware human machine inter face is achieved by means of the K ADP2 or K ADP4 interface adapters available as optional accessories e K ADP2 adapter for gateways with an RS 232 service interface and a jack plug e K ADP4 adapter for gateways with an RS 485 service interface and a terminal K ADP2 Sub D 9 pin connector 9 2m Lar K ADP4 Sub D 9 pin connector Figure 4 12 K ADP2 and K ADP4 Interface adapters 4 8 5 Accessories for RPI Devices Usually no special accessories are required for the RPI system devices All devices are supplied with remo vable terminal blocks However the following components can be ordered separately Terminal block with test sockets for HART SMART hand held terminals Removable terminal block with integrated test sockets for 2 3 mm s
117. The content of the windows should be self describing If you need further information about the content use the online help 12 3 10 1Ending the diagnostics All windows can be closed by menu commands or the close symbol in the top right corner Some windows may use the Back Close or Back to Main Menu command others Return Return to Main Menu Also some of the windows may have an end button which closes the window when clicked 12 3 10 2Simulating devices 212 Simulation plays an active part in a process A simulation of the input values can pinpoint undesirable reac tions in the control system PLC or PC system A simulation of the output values initiates the actuators opens valves and control pumps A check should be made in any case prior to starting the simulation that no system endangering or un desirable conditions a likely to arise Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface K SK1 The simulation changes 140 values independent from the process If you have the system connection to a loop contral you should be eure that the automation te oat to manual i Abbrechen Confirm the warning with OK to proceed to abort the action select Cancel If you
118. The register address to be transferred is 9 9216 9225 The rema inder from the division indicates that channels 1 to 4 of this device are represented in the low nibble of the lower byte of this register Example 2 To determine the register address for an RPI device with RPI address 27 The division RPI address 4 gives 6 75 or 6 with a remainder of 3 Therefore the address to be transferred is 9222 The remainder from the division indicates that channels 1 to 4 of this device are represented in the high nibble of the higher byte of this register Channels which are not available are set to 0 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 145 7 3 8 146 Remote Process Interface Writing Reading Binary Output Data with Status This data is deposited in register table 3 which can be read via function code 03 and written to via function code 06 This data is represented exclusively device based The switching state bit 0 and 7 status bits bit 1 to 7 are included in one data byte The exact construction is as follows awe ai Dal The bits GW1 and GW2 are of no significance for binary output signals CD1 to CD3 code the error that has occurred Q1 and Q2 provide information on signal quality Analogue input data is usually read from
119. US oder CONTROLNET can be found in Chapter 7 Gateways Note Fault elimination on the external bus system The possibilities of eliminating a bus error depend on the higher level system which is installed In the case of a redundant mode of operation gateway No 2 automatically takes over the functions of gateway No 1 if it has detected an error on the external bus The failure of bus 1 is detected by the bus master In parallel with this gateway No 2 provides a message via bus 2 Replacement of Defective Gateways Replacing a gateway The addresses and parameters for the new gateway should be downloaded via PC and PACT ware Nor mal operation is resumed A status message regarding the elimination of the fault is transmitted via the ex ternal bus Replacing a gateway external bus redundant If the system is redundant due to the use of 2 gateways and two external bus branches one gateway is defined as active priority and the other as redundant If one external bus branch or one gateway fails then communication takes place via the second gateway and the second bus branch A status message regarding the fault is transmitted via the bus branch that remains operative The addresses and parameters for a new gateway are set by means of aPC and the PACT are human machine interface Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Ge
120. a device or branch out of the current project You can either use delete or cut Delete removes the device definitely from the project cut changes the clipboard view to copy and dis plays the cut part of the project Printing a project Select Project Print to print the current project If you need to configure your printer choose Options Printer configuration The printout contains the full project tree plus some additional information Exiting the edit window Select Return Close and Return to Main Menu The edit window is closed and project manager activa ted again Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface K SK1 fm Pepper Fuchs K 56 COM Port Settings CUMI UUM 13 200 COM COMA highest RPI Address 0 12 3 5 Connecting your PC with the RPI hardware 12 3 5 1 Connection Use the K ADP2 respectively the K ADP4 interface adapter to connect your PC or laptop and the gateway 12 3 5 2 Setting the serial port Select the com icon in the project and select Device Data COM Port Settings Enter the serial port you have connected to the hardware and adjust the baud rate accordingly Confirm with OK 12 3 5 3 Starting the communication between K SK1 and RPI Select the gateway in your project This makes the menu Connection available Select Connection Establish Connection If you are working in service mode you might be ask
121. a from 1 2 or 4 channel devices is deposited in this area 2 registers must be read in order to obtain the complete information for all channels The register address is obtained from the following equation Address 2 RPI address 3 3587 The data is represented as follows Register address High byte Channel 2 Low byte Channel 1 Register address 1 High byte Channel 4 Low byte Channel 3 The data for channels which are not available is set to O Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface RPI devices with a maximum of 8 channels with status 4 registers per RPI device The data from 1 2 4 or 8 channel devices are filed in this area 4 registers must be read in order to obtain the complete information for all channels The register address is obtained from the following equation Address 4 RPI address 3 3084 The data is represented as follows Register address High byte Channel 2 Low byte Channel 1 Register address 1 High byte Channel 4 Low byte Channel 3 Register address 2 High byte Channel 6 Low byte Channel 5 Register addresst 3 High byte Channel 8 Low byte Channel 7 The data for channels wh
122. able are set to 0 RPI devices with a maximum of 4 channels 4 devices per register without status All data from 1 2 and 4 channel devices is filed in this area Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface The address is obtained from the following equation Address Int RPI address 4 9216 Int denotes division without a remainder The data is represented as follows RPI address 3 RPI address 2 RPI address 1 RPI address cht Cha If the term RPI address 4 is divisible without a remainder this implies that the data will be represented in the low nibble of the lower byte RPI address Ch 1 Ch 4 or bit O to bit 3 of the register If the division results in a remainder then this remainder describes the nibble of the register in which the data is repre sented The following relationship applies Remainder Lower byte low nibble or bit O to 3 Lower byte high nibble or bit 4 to bit 7 Higher byte low nibble or bit 8 to bit 11 Higher byte high nibble or bit 12 to bit 15 x arbitrary digit before decimal point Example 1 To determine the register address for an RPI device with RPI address 36 The division RPI address 4 gives 9
123. address 1 Register address Data byte 4 Data byte 3 Data byte 2 Data byte 1 Reading analogue input data 2 channel devices All measured values from 1 and 2 channelled devices are represented in this area as a function of the cur rent RPI address The register addresses can be obtained from the following equations Data format Register address Signed integer 2 RPI address 3 1626 Floating point 4 RPI address 3 1876 In signed integer format 2 registers have to be read The data is constructed as follows Register address 1 Register address Channel 2 Channel 1 4 registers have to be read in the floating point format These are constructed as follows Channel 1 Register address 1 Register address Channel 2 Register addresst 3 Register address 2 Data byte 4 Data byte 3 Data byte 2 Data byte 1 Data for unoccupied channels is set to 0 Reading status information The status information is filed in separate registers A register is always assigned to a particular RPI device that can have up to two channels The register address can be obtained as follows Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Register ad
124. ages Manual Address Assignment for the Devices and Subsequent Online Configuration and Parameter Assignment Using PACT are Edition 2 The device addresses are set manually Then the devices are configured and parameterized during ope ration using the RPI human machine interface This method is advantageous e if the system is to be set into operation first in the workshop outside the plant e if the device data changes frequently during commissioning e if the devices are already pre configured 1 Preparation You have set up the power supply for the RPI system Snap the gateway onto the mounting rail with the Power Rail The green PWR LED will light indicating that the power supply is present The COM Communication EXT External and INT Internal LEDs of the gateway will flash The gateway ver sion number will appear briefly on the display followed by SYN Synchronisation 2 Address assignment You now assign the device addresses manually The sequence of devices and addresses is arbitrary Now press the Mode button of the gateway repeatedly until b appears on the right hand position on the gateway display This is the symbol denoting the address assignment mode of operation The number on the left of the symbol represents a device address Using the or buttons on the ga teway select the desired address in the range 3 to 127 the address 0 is reserved for new or repla cemen
125. ain permanently connected to the RPI system as a parameterization and monitoring system it is recommended that connection is made via the RS485 service interface using the plug in screw termi nals 7 8 and 9 O In the case of the KSD GW PRO 485 gateway with RS 485 parameterization interface only the il terminal connection is available Note The jack on the front of the KSD GW PRO gateway and the screw terminal connection for the RS232 link cannot be used simultaneously KSD2 GW2 PRO Gateway The KSD2 GW2 PRO gateway is provided with both service interfaces The RS 232 service interface is connected to the jack on the front while the RS 485 service interface is connected to the terminals il Both service interfaces must not communicate with the gateway simultaneously Note Wiring The connection to the 24 V DC power supply and to the internal bus are made via the Power Rail The cable connections are made via self opening screw terminals max core cross section 1 x 2 5 mm for rigid cable or 2 x 1 5 mm for flexible cable with plastic wire end ferrule The screw terminal blocks can be pulled out of the device for easier connection Fit the gateway to the Power Rail and connect the PROFIBUS cable and if necessary the RS 232 RS 485 cable as shown in the connection diagram and the terminal assignment list The current connection plan of the gateways is given in the Modular Interface Housings catalogue PROFIBUS Transmission
126. an machine interface of your PC click on the gateway and store your configuration in the gateway using Project Download Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 185 10 3 2 186 Remote Process Interface Quick instructions 17 Installing the devices Your devices are factory set to the address 0 for the internal bus The device that is to have the lowest address should now be snapped onto the Power Rail so that the following automatic sequence can take place followed one after the other by the remaining devices in the sequence planned in the pro ject tree The gateway automatically assigns the lowest planned address that has yet to be assigned to the device with the address 0 It then automatically writes the set configuration into the device The ERR and PWR LEDs on the device concerned flash briefly then ERR goes out When the PWR LED lights continuously confi guration of that device is complete and the next device can be snapped on 18 Address 0 If you wish to use devices which are neither set to the address 0 nor to the planned project address then you can assign the address 0 yourself as described in the appendix 19 Incorrect connections See Section 10 4 Error Mess
127. and redundant design Exemplary calculation The RPIl System contains the following modules 1 KSD2 GW PRO 2 modules for gateway redundancy 10 KSD2 TI Ex 20 KSD2 CI S Ex 10 KSD2 BO Ex2 45 KSD2 BI Ex4 2 power feed modules for simple power supply 8 power feed modules for redundant power supply Device designation Overall Number Sum Number Sum length devices simple devices redundant fram simp rm KSD2 GW PRO PROFIBUS Gateway i ifi KSD2 TI Ex a KS02 C1S ExH KSD2 B0 Ex2 2 160 KFD2 EB R2A RPI 2 A Power feed module redun Lo dant sm oo 1 780 E Determining the number of Power Rails 1 For a non redundant system overall length 1 780 mm Power Rail UPR 05 length 2 000 mm 1x KF Profile length 1 800 mm 1x Power Rail PR 05 length 500 mm 4x 2 rails each fitted with VE PR connection element Assembly in typical control cabinet in 3 layers Power Rails as stated above but with 3 power feed modules 2 Fora redundant system overall length 1 940 mm Power Rail UPR 05 length 2 000 mm 1x KF Profile length 1 800 mm 2x Power Rail PR 05 length 500 mm 4x Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Planning o
128. anecenaensuaceascce ia R E EE AA A a O a iaia TE EEEE EE 45 Redundancy External BUS axccp ce cieecescstees bce seesteniodnseasieasiednwctetice sien deine dedinenn cierto anincdoenthowiectionedd usice eres ca sinntlentdelaseneiesnccesiuciesmeeegenceas 46 Determining the Number of RPI Gateways Required ccceceseececeeeeeeseeeeseenseseeeseessetserstesesssstsesssssssses 40 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com Date of issue 06 03 03 4 6 4 6 1 4 6 2 4 6 3 4 6 3 1 4 6 3 2 4 7 4 7 1 4 7 2 4 7 3 4 7 4 4 7 5 4 7 6 4 7 7 4 7 8 4 8 4 8 1 4 8 1 1 4 8 1 2 4 8 1 3 4 8 1 4 4 8 1 5 4 8 1 6 4 8 1 7 4 8 2 4 8 3 4 8 4 4 8 5 4 9 4 10 4 11 4 11 1 4 11 2 4 11 3 4 11 4 4 11 5 4 11 6 5 1 5 2 5 2 1 5 2 2 5 3 5 3 1 5 3 2 5 4 Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com RPI System Manual Table of contents Establishing the Service Functionality for the RPI System aassassnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnunnnnnnnn nnmnnn nnn Service Interface R8232 ou cececcscscece secs eeeseeceaeececeececeaeeneceeaeeceseseeseaeeeeaesaeasaaeeeeseseeeeaeecseese
129. annel can be achieved by the addition of the term 2 Channel number 1 The data is constructed as follows Register address 1 Register address Ooo Chameli Status Chamel sd Register address 3 Register address 2 o Chamel2 Status Channel2 sid Register address 5 Register address 4 Channel 3 Status Channel 3 8 registers have to be read in the floating point format These are constructed as follows Register address 1 Register address Register addresst3 Register address 2 Channel1 Dataword2 Channel1 Dataword1 ssid Register addresst5 Register address 4 Chamnel2 Dataword1 Channel2 Dataword1 sid Register address 7 Register address 6 Channel 3 Data word 2 Channel 3 Data word 1 7 3 11 Writing Reading Analogue Output Data without Status All analogue values are represented in signed integer format 16 bit and in floating point format in accor dance with IEEE 754 short real number O On the output modules in signed integer format the number of places after the decimal point il is 2 Note Device type Register content Meaning KSD2 CO Ex 327d 3 27 The content of the register is given in decimal format The values in the Meaning column are in units These can be set using the PACTware edition 2 software Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 6
130. any Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 19 2 4 20 Remote Process Interface Safety Installation Instructions for Use of the RPI System on Ships The Pepperl Fuchs RPI system must only be used in environments with ambient temperatures of 5 C to 60 C It is not suited for installation in cold locations The input voltage must be 24V 30 25 Please note the following during installation The RPI system must be installed in a metallic control cabinet A copper or steel sheet has to be mounted between the gateway or in the case of a redundant system between the two gateways and den RPI slaves Another copper or steel sheet has to be mounted between the power feed module or in the case of red undant supply between the two power feed modules and the RPI slaves The supply communication and I O lines must be screened The screen must be earthed and continued even inside the control cabinet up to the terminals see drawing In addition all lines must be damped with a ferrite e g Messrs Wurth Elektronik type 742 700 5 between the earth of the screen and the exit from the control cabinet I O lines must not be conducted past the gateway The earth connection of the power feed module has to be connected as short as possible llm AUNTIE ie an T agi o am m Tarm f y f cgpa F Ir ES TA ee a a MRA
131. arameter assignment of the Modbus gate way Time response The Remote Process Interface is deterministic The RPI devices are interrogated cyclically The most important factors which determine the time response are e the higher level host system e g PLC PC or other control system e the type and number of Modbus stations e the set Modbus transmission rate e the number of the RPI devices and the cycle time of the RPI system e the user program Further information on commissioning can be found in Section 5 of this handbook 7 3 3 Operation with a Redundant Gateway Operation with redundant gateways increases the availability of the system The gateway that is active in normal operation must have the RPI address 1 whilst the redundant gateway must have the RPI address 2 The prerequisite for the operation of a system with a redundant gateway is that the configuration data for each RPI device is stored in a file in the current project directory The following describes the installation procedure that is necessary in the case of a gateway newly deliver ed from the manufacturer If this not the case connect the Modbus gateway alone to a 24 V DC supply and depress the mode button on Modbus A for longer than 3 s This causes the current configuration here no device to be taught in In the following it is assumed that the RPI devices are pre configured and mounted on the Power Rail If this is not the case then when the active gateway
132. at of the signed integer data type there being 4 bytes per channel for the date Analogue output data with status In the case of output data with status information the DP master sends the output data to the DP slave and receives the status data as input data in the reply telegram i e the output data is in the output data area of the module and the status data is in the input area Data type signed integer 1 channel modules Output data area MSB 1 Byte LSB DATA CH1 signed integer D1 MSB 3 Byte LSB DATA CH1 signed integer D2 Input data area MSB 1 Byte LSB STATUS CH1 7 Bit o D1 MSB 3 Byte LSB STATUS CH1 7 Bit D3 Data type FLOAT 1 channel modules Module types n x 1AO_INT_S MSB 2 Byte LSB DATA CH1 signed integer Ny D1 etc MSB 2 Byte LSB STATUS CH1 7 Bit 0 D2 etc Module types n x 1AOQ_FLOAT_S The configuration of the status bytes and data bytes is the same as that of the signed integer data type there being 5 bytes of data per channel for the date Structure of the Status Information By means of the user parameter byte 11 the RPI system can be set to allow status information for each channel to be transmitted in the data telegram Whether this option is selected or not diagnostic information is transmitted via the PROFIBUS DP diagnosis see section 7 2 11 Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 4
133. ata byte 4 Data byte 3 Data byte 2 Data byte 1 Reading analogue input data 2 channel devices All measured values from 1 and 2 channel devices are represented in this area as a funct ion of the current RPI adress The register addresses can be obtained from the following equations Data format Register address Signed integer 2 RPI address 3 5126 Floating point 4 RPI address 3 7052 Two registers must be read in the signed integer format The data is constructed as follows Register address 1 Register address Channel 2 Channel 1 Four registers must be read in the floating point format These are constructed as follows Channel 1 Register address 1 Register address Channel 2 Register addresst 3 Register address 2 Data byte 4 Data byte 3 Data byte 2 Data byte 1 Data for unoccupied channels is set to 0 Reading analogue input data 3 channel devices All measured values from 1 2 and 3 channel devices are given in this area as a function of the current RPI address The register addresses can be obtained from the following equations Data format Register address Signed integer 3 RPI address 3 12 Floating point 6 RPI address 3 8210 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com
134. ateway Press the gateway Mode button repeatedly until A appears in the right hand position on the gateway display normal operation In mode A press the Mode button once again and hold it depressed until the LC display flashes Brief flashing of the LEDs is irrelevant The gateway has now accepted the existing bus structure 4 Tosetthe address and the baud rate of the gateway parameterizing interface In order to be able to link the parameterization interfaces together assign an address This address must be assigned even in the case of simple point to point RS 232 connections Press the gateway Mode button repeatedly until E appears in the right hand position on the gate way display The number on the left is the address of the parameterizing interface Select the desired address using the or buttons on the gateway The address is accepted in the gateway by de pressing the Mode button for a longer period Later on this address must agree with the entry in the pointed brackets lt 0 gt on the human machine interface Now press the gateway Mode button repeatedly until G baud rate setting appears in the right hand position on the gateway display The adjacent number on the left is the code for the parameteri zing interface baud rate Select the desired code using the 1 or I buttons on the gateway The baud rate is accepted in the gateway by depressing the Mode button unt
135. ation or the communication monitor 2 New project A new project can be configured immediately after the program start By adding the COM driver the gateways and the various devices the RPI system is installed in the project window There are three different ways to add the components e Click onto HOST IBM PC COM Driver or Gateway with the right mouse button and select lt Add device gt A menu opens in the edit window which only offers options that can be projected at this point e Click HOST IBM PC COM Driver or Gateway with the right mouse button and then click the lt Pa ste gt button down on the left The menu described above opens e Onthe menu bar click Project and then Device catalogue or simply press the function key F3 The device catalogue which contains all the installed device and communication drivers now appears in the edit window All the installed components appear in the middle column Click onto the plus sign to the left of the components to be projected The COM driver Gateway and Device subdirectories are then displayed Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Quick instructions Now the individual components should be projected i
136. ble Select in Table 03 must be set to the value FFhex The standard setting is 0 Note If the gateway is operated in this mode some gateway diagnostic functions and configuration options are not available Reading analogue input data All analogue values are represented in signed integer format 16 bit and in floating point format in accor dance with IEEE 754 short real number In the signed integer format the data is represented as follows Device type Meaning KSD2 FIEX2 527 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 155 156 Remote Process Interface The statement of the register contents is in decimal format The values in the meaning column are given units These can be set using the configuration software Reading analogue input data 1 channel devices This data is deposited in register table 3 which can be read via function code 03 The register address is dependent on the RPI internal address It can be derived from the following equati ons Data format Register address Signed integer RPI address 1248 Floating point 2 RPI address 3 1376 Only 1 register has to be read in the signed integer format In the floating point format 2 registers have to be read The data is structured as follows Register
137. ble modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface The Remote Process Interface RPI in Brief cations on both device safety and monitoring functions as well as on fault diagnosis and fault elimination O The handbook requires knowledge and experience in the field of planning configuring and il design of bus systems as well as in the field of explosion protection It cannot provide a basic introduction into the various bus systems or the fundamental principles of system planning or configuring Users who require further information are recommended to refer to the relevant lite rature the documentation of the bus and control system used or to the respective publications from Pepperl Fuchs see e g Explosion Protection Handbook Part Nr 21417 Note The RPI System Handbook provides essential information and advice on e Planning e Installation e Configuration e Operation e Safety e Detection and elimination of faults for the Pepperl Fuchs Remote Process Interface RPI This handbook applies in conjunction with the data sheets of the RPI modules that are used Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl F
138. ble modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface 7 5 3 ControlNet Address The address is set by the two rotary switches on the front of the gateway marked Node Address Possible addresses are 1 through 99 Using switch X1 the number which has been set is multiplied by 1 and using switch X10 it is multiplied by 10 7 5 4 Commissioning Before commissioning check once again that the connections are correct Familiarise yourself with the method of communication between the ControlNet scanner host and the ga teway ControlNet adapter Commissioning requires a knowledge of the the ControlNet and the parame terisation of the gateway Time response The Remote Process Interface is deterministic The RPI devices are interrogated cyclically The most important factors which determine the time response are e the higher level host system e g process control system PLC or PC e the type and number of ControlNet stations e the number of the RPI devices and the cycle time of the RPI system 7 5 5 Operation on the ControlNet The I O data is transmitted via the ControlNet scheduled service cyclic data exchange The ControlNet unscheduled service acyclic data exchange is used to t
139. can be accomplished by means of the Project upload function of the PACTare human machine interface Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 78 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Configuring and Commissioning the RPI System 5 4 2 10 Error Messages in the LC Displays of the Gateways If a device error message is communicated via the internal bus the LC display shows the address of the faulty device and the error code alternately The addresses and error codes of other faulty devices can be shown in the display by means of the W and M pushbuttons Alternately 13 A lt gt E03 The error codes have the following meanings Error code Significance 01 A device included in the gateway configuration does not exist as a station on the internal bus Device address indicates it is not included in the gateway configuration Incorrect device type p04 Device emor S O Channel error e g lead breakage or short circuit of the signal circuit of the faulty device for channel No see device LED Device in ntaisation phase 08 Device is being simulated e Redundant communication falura intemal communication P82 Redundant communication failure external communication 83 Loss of redu
140. cards of the il devices is given in Chapter 6 Parameter Assignment ie Full technical data on the devices can be obtained from the data sheets in our catalogue or from our website www pepperl fuchs com Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 39 4 2 40 Remote Process Interface Planning of the RPI System Layout and Addressing of the RPI Devices Having determined the individual types and numbers of RPI devices needed and the type of gateway re quired the possible layout of the RPl system and the arrangement of the individual devices should be spe cified Especially when several RPI systems are used we recommend dividing the RPI devices into logical functio nal units When arranging the system devices of the same type should be combined into groups The si gnals will be marshalled on the software side In this working step the RPI internal adresses should be determined and recorded in the plan see Chapter 5 4 2 1 ALLOCATION OF THE DEVICE ADDRESSES ON THE INTERNAL Bus The device addresses are organised as follows Address Device 0 Neutral address of an RPI device the setting on delivery Active RPI gateway Redundant RPI gateway 3 a 127 RPI device Table 4 3 Organisation of the RPI device addresses Determining
141. cation between K SK1 and RPI cece ceecceeeee cece eee ee eee eeee eee eaeeeeeeeeeaaeaeeeeeesaaaaaeeeeeesaaaaeeeeeessaaaees 207 12 3 5 4 Closing down the communication between K SK 1 and RPI eee cecccceeeee cece eee eeeeeeeeeaaeeeeeeeeaaaaeeeeeeesaaaaeeeeeessaaaees 208 1236 Editing Device Datla scisiacucices dente otawschsmniensinesunandpubadinsia lin nubucisnnn ubuacuunedemittaieiaiell a OO 123 0 SELECTING THE DEVICE sccixipicecpciatnccmewsadet E a E ia E a EEE 208 1239602 Changing dala seserepan EE e a EEE Er eee eer eee 208 12 3 6 3 Changing between the tab Stips csiesrrsreriseniteineeitei i a aiei e NEAT ENEE aeS 209 12364 Setting a ass WONG saarcsereatsceete cies tapetet ted aot coer cate retiree tate ate tot e dee ott net pirer neee eieiei iaren greiere 210 M22 D Oe NIO Cate eset ches anetes E enced one pace dca dianitlaat an qodeisereomnee uate E iaaasneere dean eagsadeaderden 210 12 3 7 Downloading a project into a gateway cccccecesseeceececeen eee eeeeaeeeeseaeeseeseeeaseseeaesesaneesseeesasessasesatestateess 10 1238 Pining a PO CCU eepe paireauctnsia diem eat cit snnis od a VO 12 3 9 Monitoring COVICCS agengencattescasesouecsseeenscustatuscndscataaeeseastccestauesneeaectt ahienustccavencndceequstndeestausqdeontiocedceocsmms nancies 10 1239 1 Ending the Montong sec cbecertcntceesadins saetect iie r sentenesidaccm nena e aE ara e eie SEs 211 1243 10 DIAGNOSIS OF COVICES sarciccins varisesiasidadasduWanwacvaiinestavalhe
142. cations due to technical advances Copyright Pepperl Fuchs Printed in Germany 18 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Safety 2 2 Intended Use The Remote Process Interface is a system which represents an interface between the conventional sensor and actor technology on one side and the process control system on the other side Measurement and control data is bidirectionally transmitted to the individual field devices via an internal bus and is made available to a higher level SPS or DCS Various gateways are available for the individual bus systems Connections to PROFIBUS DP PROFIBUS DP V1 MODBUS RTU MODBUS Plus and Control Net are possible Various power feed modules are available for the voltage supply They have to be chosen according to their ntended usage The maximum power supply for each line must not exceed 4 A and 2 A inthe case of red undant power feed modules The RPI system is installed in the safe area or in the hazardous area of zone 2 in accordance with the ap proval The maximum length of the RPI internal communication lines must not exceed 8 m and the cable length of the power supply 10 m Should these maximum lengths be exceeded additional gateways and possibly power supply units have to be used The protection of operating personnel and
143. ce error 20 O OO LED EXT yellow red Yellow LED External bus in normal operation Red LED No communication on external bus ere EXT Red LED Internal interface error Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 73 74 LED COM red COM OO Ore COM BO Cre COM O O INT Subject to reasonable modifications due to technical advances Remote Process Interface Configuring and Commissioning the RPI System Normal condition Internal CAN bus in differential mode Internal CAN bus in common mode redundancy failure RAM ROM EEPROM error or other internal error RAM ROM error or other error red EXT LED lights Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Configuring and Commissioning the RPI System 5 4 2 Operating the Gateways Type KSD2 GW The operating modes and parameters can be set by means of the three pushbutton switches Mode Up and Down and the 3 1 2 digit LC display The last position on the display is a letter that indicates the cu
144. ce interfaces alterna tively See Chapter 4 6 Establishing the Service Functionality for the RPI System for more information O Il Note Redundancy Considerations The planning of your application should also be considered from the point of view of availability Redundancy Internal Bus The internal bus on the Power Rail is automatically redundant A switch over to redundant communication is indicated by LED and LC displays on the gateway It is also indicated in the diagnosis window of PACT wareM The diagnosis is transferred to the control system via the external bus The user is informed of the switch over on the internal redundant channel and has time to eliminate the fault whilst the communication is continuing Gateway Redundancy The external bus can also be made redundant by using a second gateway on the same Power Rail If a gateway fails or if the external bus line is broken the second redundant gateway automatically takes over the communication Copyright Pepperl Fuchs Printed in Germany 45 4 5 2 3 4 5 3 4 6 4 6 1 4 6 2 4 6 3 4 6 3 1 4 6 3 2 4 7 46 Remote Process Interface Planning of the RPI System Redundancy External Bus Two completely isolated external bus systems should be provided if the control system will permit it in order to obtain even greater availability For this purpose a second redundant gateway is used The bus cables for the two systems should be laid on different
145. ces POPA EEE EE Manual Address Assignment for the Devices and Subsequent Online Coduinn and Parameter Assignment Using PACTwareTM Edition 2 186 10 4 10 5 10 6 10 7 10 8 10 9 Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com EMOFF NOSS AQ CS ao sauenceeeseuesuescceceecarsn at ccusis To Replace a Device while the System IS in Operation cscccceeeececeeeeceeeeeeeeeeeeeeaeeeseeeeeeeeeeneaeaees Replacing a Gateway gees ane nace E Setting Address 0 pulsing Address on a Device Deleting an Existing Gateway Configuration from Version 114 A E A E N EE Redundant Power Supply sssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnn nenn nnn nunnu nnn nn nnne n nenn mannm nn manenmane nnne nnna ma na Copyright Pepperl Fuchs Printed in Germany 174 174 175 176 176 176 178 woe 1 78 178 Via a Permanently Installed PC Based Service Level ccccccccecseceeneeeeeeeceeeseeeeeeeneeeaeseeseeaeseeaeaaeenanaaes From the Control System Engineering Console cccccecceceeseeeceeneeeeneeeeceeeeeeseaaeaeaueeeeseeeeeaeeeeanaaeesansaes 178 178 178 178 179 179 180 180 180 181 182 182 182 182 182 189 190 190 190 190 190 10 10 10 11 10 12 11 11 1 11 2 11 3 11 4 12
146. chs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 41 4 2 3 4 2 3 1 4 2 3 2 42 Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Remote Process Interface Planning of the RPI System PACTware edition 2 software with integrated HART communication DTM Cornerstone or AMS can be used on a PC with an RS 485 interface up to 250 field devices sensors or actuators HART control module KFD2 HC HAR T devices HART multiplexer master Gateway type e g KSD2 Cl S Ex H KFD2 HMM 16 KSD2 GW Figure 4 3 HART multiplexer master and HART Control module HART Transmission via KSD2 GW2 PRO Gateway The PROFIBUS DP V1 Gateway KSD2 GW2 PRO has an integrated HART multiplexer system that offers full functionality The HART protocol is transmitted via the service interface or the PROFIBUS DP V1 Service Interface The PC is connected to the KSD2 GW2 PRO Gateway via the RS 232 or RS 585 service interface The protocol is transmitted to the gateway via the service interface and further on to the RPI devices via rail 4 of the Power Rail HART compatible RPI modules modulate the data upon the 4 20 mA signal PROFIBUS PROFIBUS DP V1 supports both acyclic data exchange and logon of the servic
147. cneceeeeneeceneeeeaeeeeeeanseeaneneesaneseessatsersssseatestsesssstssses 40 Determining Where to Install the RPI System cccccceccecseeeeceseeceseeeeceseeeeansaesceeeeeesneesssanessatestsesssssssses 40 Planning the Transmission Of HART Protocols c cccccceesseceeseeeeeeeneeseaseeeensnseeaeseseeensesneesoeansessseeersees 4Q Direct Connection of a HART Programming Unit 0 ccccesseecseeseececeseeceseeeeaesaeeesaeseeaesesersneessnssessaessees 4 Connection to the HART Multiplexer oe ee nee ee E HART Transmission via KSD2 GW2 PRO Gateway PE adnate E A A E E SONICS E IOE aaee E EE 42 PROFIDU S aeoe a ee ode ewewera ie ooecek Herstieinc i cee enecte cee cniccindietieuse Seeceteaeectu cid soueetedncheweenueeceececs 42 General Information on Communication and Diagnostic Procedures via the Internal RPI Bus 43 Calculating the RPI Cycle TIME csisnaiececscncttecsectecnesnsenacesntstentiasxtncssadesteanteceieundensdubcedsaeteietadinaeeaneiareaemn AA Planning the Internal and External Communication 0 ccceecececeeenseeeeceseenseseeeesneeseeersesneesonsesnessseees 44 General Notes on Operating the Gateways ccccccceceesseceseneeeeeeeeeeeanseeaeseeaesaeseeseseeessneersssesssesessseesesases 44 Redundancy Considerations sisisncosssesansanieaiacecnineesenivarincssiecvntesieisalsataevidemstwtwed a ea ear a GO PS CU Ce Me IMEMA DUS oriai aE EEEE E E E EE 45 2 Gateway I SUI ACW code aeceesesacincscoecactcactescece
148. com The information provided in the tables below is required for the selection and parameter assignment of RPI devices See also Chapter 6 1 Parameters of the RPI Modules Device designa Type code No of available Sensor Output tion chan i settings settings Function nels Isolated switch KSD2 Bl 2or4 yes amplifier Frequency conver KSD2 FI 1 yes ter Solenoid KSD2 BO 1or2 yes driver es es no y Unit operating mode Measuring range unit con stant offset en nn es es no yes yes Transmitter 1or2 y Unit current range connection Measuring range start end power supply method 2 or 3 wire transmitters HART transmission 2 wire current source Temperature KSD2 TI y Sensor type connection method Measuring range start end converter aid unit linearization reference junction invert signal internal external Voltage KSD2 V 1 yes Unit Measuring range start end converter voltage range Repeaters Table 4 1 RPI devices and functions Type code Measu Lead Limit value Output status when fault occurs ring monitoring monitoring station TAG Brea Short Alarm Upsca Down Main As No kage circuit limits led scaled tainlast input max value charac ter Keze 32 yes vs x x PKso2 Fr 32 yes yes ves ves x x rxsp2B0 32 yes ves x x soro 32 x x x Kezek 32 yes ves ves ves x x
149. cporesducaccwsdsigpnatdaancceechansiensacceguaedescin Subject to reasonable modifications due to technical advances T 198 198 198 198 198 198 198 198 198 198 198 199 201 N ace eee pa see ae ew eee E E T 201 PE Bela hatte AN TE AE Beats ce A E A AE E 201 PANEINTA POE AE NEE tees E EA 202 EEA N ERN ATE ote EE AN A E 202 202 Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 06 03 03 Date of issue 06 03 03 RPI System Manual Table of contents 12 3 4 7 Removing a device sxiccaccusicsecccmnadergucndnindvadansseamwoiad seiansdeke dattwacaisGaiecainebndseuseauehedsainautaad SabacensbncetdeadeuMetedeegueidemaisewntecdaiag 206 12340 Pining ONO OCU serrin E EEE 206 12 3 4 9 Exiting the edit WINdOW si0cce ureccisaceeucondsnnmsctend aecheeauncecisuibemeuneeteseminaibereusaene dete scikame qeemadttwgaesmduannte nse anawenatasenccineauiatedunsacsasae 206 12 3 5 Connecting your PC with the RPI hardware 2 00 cecccecseceeneeeeceeeeeeeeeeeeeanseesesaeecaseseeseeeeesatssessssesesaesessssQO7 Teal CONE ccassctecesonsschasrecnaetoe E ceenlandas ead siosduasaiessaauamnbaacme a EE 207 12352 SEUING ING S rnal DOM sesenastesarrseet tes cnciene twitch erat um cusaveheoseateirubcadotoi aa auvnetbeputiussuiatet araea perito pir ieietu teeb areten ioiei 207 12 3 5 3 Starting the communi
150. ct window The gateway automatically obtains the address 001 while the redundant gateway ob tains the address 002 as RPI internal bus addresses 6 Select devices Open the menu or the device catalogue and mark the required device its symbol is on a blue back ground and accept it with lt Paste gt or lt OK gt the device is then inserted under the position marked on the left hand side or just drag the marked device to the project window On pasting a device to the project window PACT are automatically assigns the lowest address available to the RPI internal CAN Bus The 3 digit number appears in square brackets to the left of the device A maximum of 125 addresses 003 to 127 can be assigned per gateway for the internal bus We recommend that addresses should be assigned consecutively for similar device functions The sequence in which you arrange the devices is arbitrary The assignment to the hardware takes place during the addressing procedure Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 e Internet http Avww pepperl fuchs com 183 184 Remote Process Interface Quick instructions 7 Configuring and parameterizing In order to edit a PACT are component e click onto the component that you wish to edit in the project window with the right mouse button and sel
151. cted in this case the EXT Note LED flashes mm It is possible to simulate individual RPI modules during normal operation Bear in mind that simualted signals could interact with your process Further information on maintenance and diagnosis can be found in Chapter 8 RPI in Opera tion Indication of Measured Values Monitor Menu Device and channel specific information can be retrieved from the Monitor menu The current address of the device the device type BI BO Al AO and the channel number is shown in the LC display If an error is communicated for this address the error instead of the device type is indicated Button Up or Down next device Button OK measured values of the set device in the case of multi channel devices the Up Down buttons can be used to toggle between the channels The current measured value together with the channel number appears in the display as channel related information Channel specific errors are abbreviated and added to the channel number Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Configuring and Commissioning the RPI System OK Monitor Esc i if OK Esc res
152. d 32 d The statement of the register contents is in decimal format The values in the meaning column are given units These can be set by means of the PACTware or K SK1 configuration software Further information is provided in the description of the PAC Tware software or in Section 12 of this handbook O Analogue input data is usually read from the input registers of a Modbus station by PLC s or il process control systems In exceptional cases it may be that control of access to the input register is not supported In this case the correct register address can be obtained from Chap Note ter 7 3 13 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 147 148 Remote Process Interface Reading analogue input data 1 channel devices This data is deposited in register table 4 which can be read via function code 04 The register address is dependent on the RPI internal address of the device It can be derived from the fol lowing equations Data format Register address Signed integer RPI address 4608 Floating point 2 RPI address 3 6150 In the signed integer format only one register must be read In the floating point format two registers must be read The data is structured as follows Register address 1 Register address D
153. devices needed Chapter 5 Commissioning Configuration explains the addressing of both the gateway and the devices via the keys and the display of the gateway Chapter 6 Commissioning Parameter assignment of the individual devices describes the commissioning procedure of the RPI system via the PACTwarehuman machine interface Chapter 7 Commissioning Integration into the higher level bus system includes RPI specific information on integration into the standard bus systems PROFIBUS DP PROFIBUS DP V1 MODBUS RTU MODBUS Plus and ControlNet The various service and diagnostic functions allow you to verify and correct faults with and without the higher level bus system Chapter 8 RPI in Operation summarizes all service and diagnostic functions as well as fault signals The simulation of measured values and the display of measured values and trends are explained Appendix A Table of error codes lists all error codes shown in the display of the gateway Appendix B K SK1 Installation and operating principle of the K SK1 human machine interface Appendix C Subject index Appendix D Glossary Prerequisites for RPI System Operation The Remote Process Interface employs the most modern signal processing and transmission technolo gies The RPI assumes a central position in providing safety in hazardous areas in which control and instru mentation equipment is installed Subject to reasonable modifications due to technical advances Co
154. difications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com Date of issue 06 03 03 Date of issue 05 27 03 Remote Process Interface The Remote Process Interface RPI in Brief INTRODUCTION SYSTEM DESCRIPTION AND RPI SYSTEM COMPONENTS 1 The Remote Process Interface RPI in Brief The Pepperl Fuchs Remote Process Interface RPI is an interface system which connects the signal cur rents of conventionally wired sensors actuators and field devices on the plant side via a field bus witha process control system DCS or with a programmable logic controller PLC on the control side An RPI system consists of modular interface modules where the field devices are directly connected as well as of at least one gateway functioning as communication interface between the RPI internal bus and the standard bus for plant control PROFIBUS DP PROFIBUS DP V1 Modbus RTU Modbus Plus or ControlNet can be used as standard bus The advantage of this system lies in the fact that the expensive point to point wiring between interface level and plant control is eliminated The I O level of the DCS or PLC is likewise elimina ted By means of RPI a plant can be grouped into logical functional units Thus a clear structuring is possible PC adapter cable Gateway Power feed module 7
155. dress RPI address 2373 The data is structured as follows High byte Low byte Status Channel 2 Status Channel 1 The significance of the individual bits is given in Section 7 3 10 Writing reading analogue output data All analogue values are represented in signed integer format 16 bit and in floating point format in accor dance with IEEE 754 short real number On the output modules in signed integer format the number of places after the decimal point is 2 KSD2 CO Ex 327d 3 27 The statement of the register contents is in decimal format The values in the meaning column are given units These can be set using the human machine interface Writing reading analogue output data 1 channel devices This data is deposited in register table 3 which can be read via function code 03 and written to via function code 05 Preset Single Register and function code 16 Preset Multiple Register The register address is dependent on the RPI internal address It can be derived from the following equati ons Data format Register address Signed integer RPI address 2 Floating point 2 RPI address 3 126 In the signed integer format only 1 register must be read and written to In floating point format 2 registers have to be read written to in order to access the data from an RPI device The floating point format data is structured as follows Register address 1 Register address Data byte 4 Data byte 3 Data byte
156. dual channel il The flashing red LED s on the RPI system should not be allowed to cause confusion They do not extinguish until commissioning is finished Note 5 3 2 LEDs on the Front Panel of a Device There are between three and six LEDs on the front panel of a device which indicate the current status of the device as well as hardware and communication errors The following symbols are used in the descriptions below C LED off Flashing LED O LED constantly illuminated Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 69 70 Remote Process Interface Configuring and Commissioning the RPI System PWR No voltage supply OO Do O Voltage supply present ERR Setting and checking the device address DPO No error DRD ERR Do O Bus error s ORD ee Oe Hardware error specification via LED IN CHK or OUT CHK ERR LED s IN CHK or OUT CHK 1 4 oe Input Output channel 1 not active Ore o OO So OO Yellow LED Input Output channel 1 active Red LED Lead breakage or short circuit in the field circuit channel 1 Red LED 1 and ERR LED EEPROM error Yellow LED 1 and ERR LED Communication error Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in G
157. due regard for the recommendations of the organizations for PROFIBUS MODBUS and ControlNet When screening the signal cables between the RPI modules and the field devices the screen of the cable must be located at the earthing connections of the field devices If bus cables with a double screen are used e g wire braiding and metallic foil both screens A must be connected together at the cable ends with a low resistance connection when preparing the cable Note Power supply cables are a source of much interference radiation e g the starting current of a three phase motor For this reason parallel cable routing of supply cables and data signal ca bles should be avoided especially within the same ducting Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Planning of the RPI System 4 11 3 Preparing the Wiring Please refer toChapter 4 11 1 General Information on Device Connection Ex side On the Ex side the cables are laid from the field devices to the corresponding blue terminals of the RPI de vice Marshalling of the field cables is not necessary it is carried out by means of RPI internal addressing Non Ex side e Onthe non Ex side it is merely necessary t
158. e Up and Down External communication LC Displa External address status LED green Power zai a i LED red Communication all LED red k r internal A s NORN B aeaii ETOR bet R Gime r LED yellow red H BALD EKT F External bus Button Mode aan 9909 93939323939 399 3939 RS 232 3 5 mm oiii rii a IAR P Button Down Figure 7 7 KSD2 GW CN gateway Features of the KSD2 GW CN KSD GW CN 485 gateways The KSD2 GW CN and KSD2 GW CN 485 gateways connect the RPI internal bus to the external Control Net bus The gateway thus assumes the master function for the internal bus The gateway has the function of a ControlNet adapter slave on the external ControlNet To increase system availability the gateway and external bus can be arranged redundantly The gateway is provided with two BNC plugs for the connection to the ControlNet The cable to the Scanner node ControlNet host may be arranged redundantly by using both connectors A and B The MaclD ControlNet Node address can be set by means of the two decimal rotary switches before switching on the power supply The addess range is 1 through 99 A configuration tool for system configuration or problem solving can be connected using the NAP interface Network Access Port 7 5 2 Device connection The electrical connection of the ControlNet gateway by means of a BNC plug and a RG 6 four core scree ned cable merely involves establishing
159. e LF com 1 COM Port RPI OG koom Ksb2 Gw MOD 4 Building 1 1 a vernmacnmer ei 7 General Settings E 5 KSD E MeGstelle Projectmanager E Mefstelle allways on top O 03 6502 61 Connection Establishment G Bpee KSD X read TAG names on connection OF Show details 12 3 11 2 Getting help Use Help Contents or Help Search For Help on to get the build in online help Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 214 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface K SK1 12 3 11 3 Finding out the version of your software Select Help About K SK 1 Adialog appears stating the version About this program x i Program for the configuration of the REMOTE PROCESS INTERFACE of Pepperl Fuchs Version 2 3 IF you have questions or probleme please call 49 621 7 76 0 Confirm with OK to close the dialog box 12 3 12 Exiting the K SK1 software Select Project Exit Or Exit Exit Program to close the program You can also use the close box of Windows If you have made any changes to the project you want to keep make sure to safe the information first If you confirm the dialog box with OK the program is quit and all unsaved data lost Subject to reasonable modificati
160. e gateway It is im portant that the device data are stored in the gateway i e using Save to device or Download otherwise the new device will have nonsensical data written to it Devices of the same type can be exchanged while the system is in operation providing they have the address 0 new device The new device is then automatically assigned the address and related data of the old device If more than one device of the same type are exchanged then you must install the replacement device that is to receive the lowest address first since the gateway stores addresses in the devices in order of ascen ding addresses The address of previously used serviceable devices which are to be stored should be set to 0 so that later they can be incorporated into a new system without problem Replacing a Gateway Replace the gateway and set the correct address Mode E and baud rate Mode G on the new gateway as described above for the parameterizing interface Connect your PC to the parameterizing interface using the cable Start the RPI human machine interface on your PC load your project and store the data in the new gateway using Download Of course you can also pre configure the new gateway in this way in the workshop and use it later in the system without further processing Setting Address 0 Deleting Address on a Device When supplied the devices have the address 0 This address can
161. e interface as class 2 PRO FIBUS master in conjunction with PAC Tware edition 2 or with any other FDT compatible human machine interface To enable the gateway and a PC to communicate via an external bus it is necessary to integrate the communication DTM This DTM allows the transfer of the HART protocol to the class 2 master via acyclic data exchange Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Planning of the RPI System up to 250 field devices sensors or actuators Gateway KSD2 GW2 PRO Service interlace R5232 3 5 mm jack bush Service interface RS485 PROFIBUS DP V1 Figure 4 4 PROFIBUS Gateway KSD2 GW2 PRO 4 3 General Information on Communication and Diagnostic Procedures via the Internal RPI Bus Communication via the internal bus is completely controlled through the RPI gateway The gateway ma ster communicates cyclically with every RPI station slave Extensive diagnostic information can be retrieved for each individual device via the external bus system to the higher level host For this purpose we advise using the PAC Ture edition 2 human machine interface il Further information can be found in Chapter 7 Integration into the Higher Level Bus System Note Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 e USA
162. e register address is dependent on the RPI internal address of the device and the channel It can be de rived from the following equations Max Channel No Register address 8 RPI address channel number 1 8 4 4 RPI address 3 channel number 1035 The RPI address can be in the range 3 to 127 The information is represented as follows o o0 ojoj o jojo oj o jojo jo o o o cnt Reading a number of channels and or status information This data is deposited in register table 3 which can be read via function code 03 and written to via function code 06 O Analogue input data is usually read from the input registers Table 04 of a Modbus station il by PLC s or process control systems In exceptional cases it may be that control of access to the input register is not supported In this case the correct register addresses can be Note _ obtained from Chapter 7 3 13 RPI devices with a maximum of 8 channels 2 devices per register All data from 1 2 4 and 8 channel devices is filed in this area The register address is obtained from the following equation Address Int RPI address 2 2 9345 Int denotes a whole number of rounded down The data is represented as follows RPI address 1 RPI address ch Cha It should be noted that fundamentally only even RPI addresses are represented in the lower byte of a re gister and odd RPI addresses in the higher byte Channels not avail
163. e tipped at an angle but pressed on to the moun ting rail in a vertical attitude If the UPR 05 is being used it must be remembered that the cover must be fitted to provide protection against accidental contact 1E Aii Correct Incorrect Device installed vertically from Device inserted at an inclined above attitude Figure 4 17 Installing the RPI devices Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 63 4 11 5 4 11 6 64 Remote Process Interface Planning of the RPI System Figure 4 18 Installation of the RPI modules il When installing the modules please consider the specifications stated in the previous chapters regarding the power supply segments and the internal RPI bus stations Note Connection to the Control System The connection of signal lines from the field devices is completely eliminated since the RPI system converts the field signals into standard bus signals Only the bus line from the RPI Gateway has to be connected No input output units are required on the control system or PLC An appropriate bus master assembly must be provided in their place The manufacturer will provide information on which bus system is appropriate and available for a given control system Connecting the Power Cables and Signal Cables
164. eaeeeeseaeeeeesaaaeeeeeseneeeeeas Error Detection Using the PACTwareTM Human Machine Interface ccccsccececceeeeeeeeeeeeeeeeseceeeeseaeeeeeeneneeeeeas Replacement in the case of failure Of an individual device cc cc cccccceeecceeeeeeeeeeeeeeeceseeecessaecessaeeeesaeseeseeseeseeeeees Replacement in the event of the simultaneous failure of a number Of devices ccceececseececeeeeeeeeeeeeseeeesseeeeees Error detection on the external DUS system s sssssnssnuunnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnn nennu nnmnnn nnmnnn mnnn mn nn n Fault elimination on the external bus system ssssessnsunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nunnu nnmnnn nenn nenna nnm na Replacement of Defective Gateways cccsecscseeceeeseseeeesneneeseneeeeseeeeeeseesesnseeaesneeaeaseaeaegaeoeaesseenenesaeas DISMANTLING AND DISPOSAL vuccccccccccccnccsncsensccccceccecensensenansensansenecsensecensennenansnnseeenseesenss APPENDIX QUICK INSTRUCTIONS sipcencisicicecthsaceiessseii eras seethedoustens teveleesieneesineidivaaetteuntalatcusssanaeeetinieds Installation of the Software ON your PC 1 20 cccsceceeeeeeeeeee seen neces eneeeeneeeeaesseeeneseeaesnseoeaseaeaeseseeaesnaeenaeeanas Voltage Supply Tor the API SYSTEM sissscssccctvadetncievecenccesesccucases a E A E a i Configuration and Parameter Assignment of the RPI System ssussssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn ennnen Offline Configuration and Downloading to the Devi
165. easonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Remote Process Interface K SK1 The Enumerate tab strip is useful in numbering channels T Enumerate Charmels C marked only You can automatically number the channels consecutively by pressing the button Start K If you choose to enumerate a range of modules the channels of each module are numbered separately starting from 1 The Sort tab strip is not implemented in this version The last tab strip is Auto Name which allows you to fill the TAG field of all devices with a string and an au tomatically added number automatic Naming Prete x Start number omo Step f 0 Al i marked onki Unlike enumerate the Auto Name function influences all devices You cannot select a range The auto name function is started by pressing the Start Q button After you have finished the configuration press Finished Start g O This is only a basic set of information stored in the devices Use Device Data Edit il Device Data to edit the complete information of the device Refer to section XX to find out how to edit the full information stored in the devices Note Removing a device Before you remove a device make sure that you selected the correct device s There is no undo function available There are two ways the remove
166. eaueceseaeeneceseansceseaeaasesaeaneasesasaaeeessanessssssassstssasaseses LOQ Gateways of Type KSD2 GW2 civesastaciadansvccscnamenseserasnnincanaaisctecaaceaximlastieaiateltsnucsrsiuianmers maancmviicercaanneeade 10 Data Formats paar E EE TE E EE A A TE E E ES E EEEE WA Status intormmation Of Process Data ismscorassrisersnrei innar n a a a a a a a i Me Operation with a Redundant Gateway ccccccccsesececeseeneceseeneneceseeneeeseaesaseeseanesesssteaeessssseseseasesestsssssseee 1 12 Exchanging a GOW AY och srsrei teeec ices astrnawccet ch petensceeumvelvine i a a O Exchanging a Gateway External BUS Redundant cc cececceeececeneeeeeeeeeeesnseeaeseeserseseeersneesstestessseseees DIO Gateways for PROFIBUS DP aadi EO E E E A E E O Nt Gateways KSD2 GW PRO and KSD2 GW PRO 485 Seeded Sec apse tees nena ens dees E ET UG Gateway KSD GW2 P O sccecssesencentsannscine toonceseuspnesdseeSiawabste tebe sndeemmns sey se cntemedsadachesacaenaesdssmeiGesadseeesdandeecsals 1D General Notes on PROFIBUS DP sisscascsscsscceusecesssazscsandedinacsinsaicdunessaededacetadsiacsdeadeserseuaseactencmaacreacarecreoaes 1D FEATURES OF THE PROFIBUS GATEWAYS wasscscscconcecencncnancncunsnensnsenensnsnnssansnsusnnssannenansnssasnenansssensssssnsssensees 116 Device Connection ies E RET EOE ES E E E E EEE LO Gateways of Type KSD2 GW PRO and KSD2 GW PRO O 485 0 0 ceccccsseeeececeeeeeeeneceeeeceuaeeeeesaeeeeeeseeeeessaseeeseseneee
167. ect Edit or e double click the component that you wish to edit in the project window or e click onto the component that you wish to edit in the project window with the left mouse button and then click the Edit button down on the right in the project window or e click onto the component that you wish to edit in the project window with the left mouse button and then depress the function key F5 Now the display and interface of the Device Type Manager opens providing the Device Info Descrip tion and Parameter tabs for offline parameterization The Device Info tab provides unchangeable information on the selected component The Description tab can be used to store data which is specific to a measuring point e g tag name and measuring point description This information is only stored in the project not in the devices The Parameter tab provides access to all settable parameter values of the selected components In formation which is not changeable is displayed in light grey on this tab The data on this tab can be e stored in a file e stored in the device When you click the Save to device button PACTware edition 2 establishes a connection to the sel ected device and loads the data to this device O The Save to file or Save to device function stores the data of the activated device or the COM il driver exclusively The remaining project data is not stored Note This means that in a project consisting of a COM driver and dev
168. ect manager sucssccssaiensniecacscoscunadeswanddasinesseideadmadeelantieewsetes The men Dar sani ncessecvcntetedeaacbreantasnsenentesesirentencdsecateies anesecareo enue The short cut buttons cuxicccrcanorscanacadecsenean teutenbiscneaseinneanaatemnnobeeemens The TING Dar aecsete seatetascttee senencetvect naei e E iE iaae Selecting an item secdicswaenseosdenwsccxedvancosiwaneutdeduenssedinenteexduecdeubonenscdes The structure level buttons cceccccseceeeeeeeeeeeeesseeeeeneeeeeseeeeens The Show details check DOX ccccssseeeeeeeeeeeeeceeeeeeseeaeeeeeeaees Handang Me GOlOGCE sis xesecste cot sentnsteectos teats aces O E E E S muda ne OVC case tae oder ss E E Creating a NEW project ccsecccsescececeseeecceesseeeseeeeeceeaseeeeseaeeess Opening AN existing project ccccccsseeeeeceeseeeeeeeseeeeeneeeeeesaaeeees SAVING A PrOjJECE sescsdedcotsseindamiencedyncnamausndendancerexenanasaasieadualaatacies ENA POSO Zao E E E eee aeeteacaeces The three parts of the edit WINGOW ccccceeceeeeeeeeseeeeeeeeeeees Selecting the active part of the WINdOW ccscccesseeeeeeeeeeeeees Getting AS UD are atprtcdintgim ence totecncesaeieeweadtbacnsacsecdesnccasssncnoccesenaetcodasecemedes Undoing CHANGES sea ccc sncemanmtentrcunedes Jasissioamerdteacsenaeatwaceereest lt amnonened Adding A CC VICC rnsiiasaisuscnacinedinndeteenestanbandiandasnscidesgedhetceeetaincinentine Configuring a device sepsdewsisi
169. ected at this stage In order to be able to link the parameterization interfaces together assign an address This address must be assigned even in the case of simple point to point RS 232 connections In the diagram it appears in pointed brackets lt 0 gt The selected address must correspond with that set later on the gateway When closing the window save the data of the gateways to a file offline or to a device online as in the case of the COM port parameterization Any names can be used for the files but the file extension is always dat To set the address of the parameterizing interface for the gateway The address for the parameterizing interface lt 0 gt is given in the pointed brackets in the left window of the main menu adjacent to the symbol for the gateway This must agree with the setting on the ga teway in mode E If this is not the case select Device data RPI settings or Device data Edit device data depending on the version Set the correct address for the parameterizing interface in the Communication tab To set up the gateway connection Click on the gateway symbol in the left window of the main menu and select Connection Establish connection The symbols for the devices appear in bold text When you are asked whether you want to copy the set gateway configuration into the project you must respond with Yes in order that the configuration data from the dev
170. ectly via the bus system The PC functions as class 2 master and transfers the data acyclically to the gateway via the PROFIBUS Further information can be found in Chapter 7 2 2 Gateway KSD GW2 PRO Power Supply All RPI modules are supplied with 24 V DC voltage via the Power Rail Power supply is provided via power feed modules which are mounted on the Power Rail too Suitable power supply units are available for the connection to 230 V AC These supply the Power Rails with power via power feed modules Alternatively they can be mounted directly on the Power Rail Note that no power feed module should be operated under zero load conditions since this can lead to spurious tripping of the error signal red LED ERR relay output At least one RPI device or one RPI gateway should always be connected to each power feed Attention m od u e Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 4 7 1 4 7 2 Remote Process Interface Planning of the RPI System O Detailed information on power feed modules and power supply units can be obtained from the il data sheets on our website www pepperl fuchs com or from our catalogue A list of the indivi iss dual devices is provided in Chapter 3 3
171. ed Pepperl Fuchs K System In the case of a mixed application of K System modules and RPI modules the K System modules are likewise supplied via the Power Rail But they are of course not connected to the RPI internal bus A transmission of a combined fault indication of the K System via the RPI power feed modules is not possible Other systems The interface modules can be mounted mechanically onto the mounting rail Power sup ply and signal transmission must be connected separately from the RPI system O il A simultaneous transmission of combined fault indications and the HART protocol via the Power Rail is not possible Note Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 53 Remote Process Interface Planning of the RPI System 4 8 2 KF Profile with Integrated Cable Ducts The KF Profile is an aluminium extruded section which provides a space saving installation of the RPI sy stem The profile contains three main components see Figure Figure 4 10 e Large cable duct for routing the cables from the field side e Small cable duct for the cables of the power supply and of the external bus to the DCS or PLC e Integrated mounting rail for installing the RPI modules above the cable ducts The PR 05 Power Rail is inserted into this
172. ed to enter a password if the option is activated in the gateway Setting this option is described in section XX Confirm your password with OK This password does not appear in maintenance mode If you do not posses the password exit the program and start in maintenance mode again Password Dialog Please enter the 4 letters password The next dialog box appears if the project configuration in your PC differs from the hardware setup Important Question Project configuration differs from target configuration of the gateway Should the target configuration be copied into the project 7 Select yes if you want to upload the hardware configuration into your present project no otherwise If the project and the configuration of the gateway are the same or you chose to upload the configuration a dialog box appears stating that the connection is established Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 207 12 3 5 4 12 3 6 12 3 6 1 12 3 6 2 208 Remote Process Interface K SK1 Connection establishment done All devices appear in black bold letters in the program manager If there is a difference between the confi guration in the gateway and software or a device is not working correctly the affected device appears in red letters f
173. eeas 116 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com T 125 2 7 2 9 3 7 2 6 7 2 1 7 2 8 7 2 9 7 2 9 1 7 2 9 1 7 2 9 2 7 2 9 3 7 2 9 4 7 2 10 7 2 11 7 3 7 3 1 7 3 2 7 3 3 7 3 4 7 3 5 7 3 6 7 3 7 7 3 8 7 3 9 7 3 10 7 3 11 7 3 12 7 3 13 7 3 14 7 3 15 7 3 16 7 4 7 4 1 74 2 74 3 74 4 7 4 5 7 4 6 7 5 7 0 1 7032 7 9 3 7 0 4 7 9 9 7 9 6 7 9 1 KSD2 GW2 PRO Gateway Wiring PROFIBUS TRANSMISSION PATE cesceccccccccccuncnnnnnencnensesnsnsnsnsnunnnnenenensnsnsesnsnsnsnunununanaensnsnsnssenenenenuausunenssnsnss CES SUNG and EMO gecaiececrde ae asserts ocecieasclos sceneries xanes e aaa E EA EE EEEE NERS aaa a Eae aiaa asaina GSD Files Caiado of the e Cyclic C COMMUNCAUOI sort seisicciceectes apices the ticeiee daotew seks afte seethcoewien cei EE E E Representation of the Gateway in the DP Master System Representation of the RPI modules in the Gateway Data Structure on the PROFIBUS Format of the Input and Output Data Structure of the Status Information Commissioning GATEWAY SPECIFIC DIAGNOSTIC INFORMATION KSD2 GW MOD and KSD2 GW MOD 485 daewo for the Modbus RTU nasssnnnnnnnnnnnnnnnnnnnnnnnnnnnne Device Connection Commissioning a a Operation with a Redundant CaNT Operation on the Modbus
174. eeeeeaeeesaasessseneneseaesessenessaeness 9 Successive Assembly of the RPI Devices Configuration and Parameter Assignment via PROFIBUS DP V1 Configuration and Parameter Assignment via PROFIBUS DP and GSD 081 ais aa Subject to reasonable modifications due to technical advances Xe N N Date of issue 06 03 03 92 N Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com Date of issue 06 03 03 6 6 1 6 1 1 6 1 1 1 6 1 1 2 6 2 6 2 1 6 2 2 6 2 3 6 2 4 6 3 6 3 1 6 3 1 1 6 3 1 2 6 3 1 3 6 3 2 6 3 2 1 6 3 2 2 6 3 2 3 6 3 2 4 6 3 3 6 3 4 6 3 5 6 3 6 6 3 7 6 3 8 6 3 9 6 3 10 6 4 6 5 7 1 7 1 1 1 1 2 7 1 3 7 1 4 LLS 7 1 6 7 1 7 7 2 7 2 1 7 2 2 7 2 3 7 2 4 7 2 0 7 2 5 1 RPI System Manual Table of contents PARAMETER ASSIGNMENT vasccccccccccccnccncceccsnnscnencensecencensennenansnnssnessensecencensennennnsnassnssesssseessQo Parameters of the RPI Modules cccsssccsssnssneecsecennsnsnesesenescenesecanencnansceanasanassananaeanseeaceecueesesansasanssnas Qo The PACTwareTM Parameterization Window ccccceccscecesseeececteseeeeeaneetneeeeeeteseeaneesesteaseesestesseeaeetseses 1 OO Parameter TaD ceceuaiticmasercaichadanconcse aucamnin EE ER E AEE acannon 93 POPs TA De E E E E Meenteacbeasasteereeuss 93 Editing a PROSE cepccececpmectce
175. el 1 High Signal Alar C Channel 1 Signal over Mes A O Channel 1 Signal under Me O Internal bus eror CAN H O Intemal bus eror CAN L 2 C Internal Memory Error vr eae J bs F i 0 10 0 20 0 30 0 40 0 50 1 00 ime IL BANTAL ie Cyclic refresh data Oo __ Help Close Figure 8 3 Window showing the display and the trend graph The Display section enables you to select the measured values the messages and limit values that are to appear in the Trend section on the right To do this check the box on the left of the value that is to be dis played Use the Delete button to remove selected values and the Reset button to undo changes These options are only available if the Cyclic update checkbox is not marked Individual values can be shielded during the recording phase by clicking onto the checkboxes under the re corder and thus removing the check marks The colours of the boxes correspond to the colours of the re corder graph The order of the colours from left to right corresponds to the measured values selected in the Display section from the top downwards Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 175 Remote Process Interface RPI in Operation 8 3 Simulation 8 3 1 Simulation of Input Signals The control system can
176. eld De vice Tool independent of the manufacturer and the f Subject to reasonable modifications due to technical advances ieldbus Based on FDT technology Device Type Managers DTMs available for all Pepperl Fuchs devices and systems Commissioning configuration and parameter as signment independent of the process control sy stem Communication DT Ms available for serial inter face and field bus systems PACTweare EDIT ION 2 i BASIC VERSION PAGT yos ae nangen pt by garer r i paik Maintenance diagnostics and fault handling Suited for PCs running Windows 98 Windows NT Figure 4 11 PACT pare M the human machine in Windows 2000 and Windows XP terface for be Remote Process Interface In accordance with VDI VDE 2187 Hardware requirements Operating system Languages Licensing Schematic representation of the system configuration System planning project processing PC with Pentium Il 200 MHz processor 64 MB RAM minimum Windows 98 Windows NT 4 0 Service Pack 4 or later Windows 2000 and Win dows XP German English and French can be set The packages point to point Interface Technology point to bus Remote I O point to bus HART and Level are available separately or together as download http www pepperl fuchs com pa accessories pactware main html in a BASIC ver sion without the functions Print and Save The BASIC version can also be obtai
177. ent as a symbol in pointed brackets or lt 1 gt The software assigns different addresses to priority and non priority devices and it always assigns the lowest free address lt 3 gt to lt 127 gt to devices that are inserted 2 Address assignment and prioritization When operating with redundant gateways the gateway having the address 1 is the priority gateway that with the address 2 is the non priority gateway During fault free operation both gateways transfer the data from the field to the control system via the external bus In order to avoid conflicts data from the control system is passed to the field exclusively via the priority gateway It is only when this path is interrupted that data is passed to the field via the non priority gateway Now press the Mode button on the non priority gateway repeatedly until b address assignment appears in the right hand position on the gateway display Using the 7 or buttons set the address 2 on the left hand side of the display Press the Mode button for longer than 3 s The address is accepted into the gateway Address 1 is automatically assigned to the priority gateway 3 Editing RPI components Mark the devices in the project window in order and open the tabs for editing these devices When parameterizing the two gateways it should be noted that the addresses for the higher level control sy stem must differ Similarly if a serial RS485 inter
178. er However it is also possible to assign the addresses manually to a specified input and or output address range The data without status information from binary devices occupies one bit per channel The switching state of the lowest channel number is located in the lowest bit The efficiency of a data transmission can be increased either by packing a number of RPI modules into one DP slave module or by using multi channel RPI modules since otherwise only one bit would be occupied whereas one byte is required for the trans mission The data transmission with status information occupies one byte per channel The switching state of the channel is located in the lowest bit and the remaining bits transfer the status see Chapter 7 1 Status De scription The data of the analogue devices is transmitted in decimal format DEC Temperature values are transmit ted in the signed integer format at a factor of 10 whereas current values are transmitted at a factor of 100 Data transmission requires 2 byte in the signed integer format and 4 bytes in the FLOAT format For a status information an additional byte is required which is placed in front of the data bytes adding up to 3 or 5 bytes per transmission Address Type Description Address Length Length Cn kozo 200 mwe n2 kso2mnEex ian J 2 2we _ Ksp2com wom gt gt w O 2ye O OOO O 32 Ksp2com tAOrLoaTS 5 3 mws
179. ermany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 7 3 9 Remote Process Interface RPI devices with a maximum of 8 channels with status 4 registers per RPI device The data from 1 2 4 or 8 channel devices are filed in this area 4 registers must be read in order to obtain the complete information for all channels The address is obtained from the following equation Address 4 RPI address 3 3084 The data is represented as follows Register address High byte Channel 2 Low byte Channel 1 Register address 1 High byte Channel 4 Low byte Channel 3 Register address 2 High byte Channel 6 Low byte Channel 5 Register addresst 3 High byte Channel 8 Low byte Channel 7 The data from channels which are not available is set to 0 Reading Analogue Input Data without Status All analogue values are represented in signed integer format 16 bit and in floating point format in accor dance with IEEE 754 short real number O In the signed integer format the number of places after the decimal point depends on the RPI il module The KSD2 TI Ex universal temperature converter operates with one all others operate with 2 places after the decimal point Note In signed integer format the data is represented as follows Device type Register content Meaning 32
180. ermany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Configuring and Commissioning the RPI System 5 4 Configuration In Chapter 4 Planning of the RPI System of this handbook the layout of the RPI system was planned The RPI devices and gateways the voltage supply as well as the addresses for the individual devices were de termined The basic configuration of the system is described in this chapter The following table provides an overview of the configuration steps and the respective menu items for configuration directly on the gateway Configuration step Menu item for gateways Menu item for gateways KSD2 GW SD2 GW2 Addressing the gateway on the internal bus RedMode address 1 prior 2 redundant i 4 Set RPI internal address for the devices addresses 3 127 EE ee AdrAssign Addressing the gateway on the external bus a a Addressing the service interface ParAdr Setting the baud rate for the service interface ParBaud Only MODBUS Setting the baud rate for the external bus rr ee Only MODBUS Setting the parameter values for the external bus Optional Uploading the current RPI device configuration to the A then press Mode Teach In gateway button gt 3 sec Note Normal operation mode of the gateway Run Tabelle 5 4 Configuration procedure
181. ernet http Awww pepperl fuchs com 27 3 2 3 2 1 28 Remote Process Interface Product Description Performance Characteristics Overview of the RPI System Characteristics Power feed modules Power supply units e Gateways RPI devices Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 2 Aor 4 A output current 24 V DC power supply Supply of the RPI modules on the Power Rail Group fusing via a fine wire fuse Alarm relay output for defective fuse 4 A output current at 24 V DC output voltage 90 to 253 V AC input voltage Supply for the modules on the Power Rail Group fusing provided by miniature fusing Master function for the RPI internal bus Couples internal bus to external standard bus system External bus systems PROFIBUS DP PROFIBUS DP V1 with HART transmission MODBUS RTU MODBUS Plus ControlNet Slave functionality on external bus Storage of the configuration and parameters of all RPI modules in an internal EEPROM Configuration of the overall RPI system both via integrated RS232 or RS485 service interface and external bus Diagnosis and error messages via LEDs and communication via external bus and the service interface Redundant external bus with second gateway 1 4 channel interface modules for the transfer of digital and analogue I O data bet
182. ers during the configuration of the RPI system In normal operation run appears in the display On depressing the OK button the data menu which displays the operating data appears Using the key combination Esc OK the service menu appears It enables you to carry out the settings for the configuration data LED red Communication LC Display LED red a Button ESC Internal communication LED green Button Up P i Power supply Button OK LED yellow red External bus Button Down AS E AN I tae eo f RS 232 o ofio n a Rotary switch 3 5 mm Jack bush i termination resistor Sey GULL for PROFIBUS RS 485 Removable terminals Serviceinterface green Figure 5 7 Front view of KSD2 GW2 PRO Gateway Normal Operation Run Menu During normal operation the information run appears in the gateway LC display The following diagram shows the menu logic of the gateway The commands in the middle of the arrows represent strokes on the corresponding keys of the gateway In general the following applies to the com mands e OK guides the user to the next operator level or confirms an input e Esc guides the user back to the preceding operator level or aborts an input e Up and Down pages the display elements or input values within each operator level e Esc and OK depressed simultaneously guides the user from the normal mode to the service mode where inputs can be made Subject to
183. erved 001 1 Bit 010 2Bit 011 4Bit 100 1 Byte 101 2 Byte 110 4 Byte 111 Reserved Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Type of error Gane Ore reserved Tiec Ther lead short circuit 2 jet Zines under voltage 3 dec Shey over voltage 4 jec 4 hex overload Ideg Die over temperature 6 dec Grex lead breakage Ideg Trex upper limit violated Cues Gex lower limit violated Dade Irex error Oia Anex reserved odes Rex reserved 16 gec 1 On ex upper alarm limit violated pees e lower alarm limit violated 18dec 12hex top of range violated Tisha Shey bottom of range violated 20 tag 14hex not used 31 dec hes not used C The diagnosis diagram contains a maximum of 64 bytes i e if more than 13 DP modules deve il lop a fault the gateway cuts off the information after 64 bytes Note Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 e Internet http Avww pepperl fuchs com 133 134 Remote Process Interface Summary of the structure of the standard diagnosis for the RPI system Structure o
184. es e Physical unit of the analogue input parameters e Hysteresis for falling short of exceeding the limit value e Lower and upper value of the measuring range 0 measured value or 100 measured value e Inversion of the input signals e Cold junction compensation internal external e User specific linearization e The input value can be overwritten in a defined way for simulation purposes 4 1 5 4 Device and Channel Specific Diagnostic Information The diagnostic information contains detailed data on device and channel status e Internal device error messages status of the bus communication configuration errors e Separate messages for lead breakage and short circuiting e Overrange and underrange alarm alarm for exeeding falling short of limit value Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 37 Remote Process Interface Planning of the RPI System O Detailed information on the data structure of the individual modules is given in Chapter 6 Parameter Assignment Note 4 1 5 5 Overview of Functions and Miscellaneous Functions for Each RPI Device 38 Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs
185. es electroma gnetic compatibility O Information on the construction of a screen is given in the PROFIBUS directive PROFIBUS DP il FMS available from PNO order No 2111 Note The gateway are provided with two ground terminals 15 16 These terminals have to be connected to ground at the place of installation O If cables with a double screen are used e g wire braiding and metallised foil both screens must be connected together at the cable ends with a low resistance connection when making i up the cable ote Power supply cables are a source of much interference radiation e g the switching current of a three phase motor For this reason the laying of supply cables and signal data cables in paral lel runs should be avoided especially within the same ducting 7 2 8 GSD Files Pepperl Fuchs provides 2 different GSD files for the configuration of an RPI Profibus gateway e the PF0818 GSD file e the PF0818P GSD file If the PF0818 GSD file is used e aparameterization of the RPI devices by means of PAC Tware is obligatory e upto 8 RPI devices can be allocated to 1 PROFIBUS DP data module pack This is obligatory if there are more than 64 RPI devices on a gateway e Incase a gateway has to be replaced the new gateway should be parameterized via the service inter face no parameterization via PROFIBUS Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepper
186. eseaeeeeaeeeeseagenes SEICE MI CRC TAO searches scien seco ccna ct osaecerestens ae en ag sense see oe eneswe vee cece eens epee enconseseace cesses PROFIBU DE reece sree crc esc S earns ae eo es emidah cdene nm ncamencawtnens ieaeeanecanceeueeeesest PROFIBUS DE VI oarre beceteeie atc cidace ectee E E E EEEE POWER SUPPI danna a r E A bunen aeckeuanetenatusnzoens Construction of the Power Feed Module cccccccceseeceeeeceeeeeeee cece eeaeeseeseseesaeeeaeeeeeaeeseaaeseeaeesseseegeseeananes Group Fusing on the Power Feed Module cccccseeceneseeeeseeeeceecececuesecesaeeceseseeseaaeseanseeessetseeaneeeesaneaes Segmentation of the RPI System sees E Power Feed Modules for Redundant Power Supply Setting up the Power Supply Balance for the RPI Devices s Including tt the BCN PE EE E TEE Determining the Power Supply Segments l PENNAT Establishing the Type and Number of the Power Supply IV Modules T Establishing the Type and Number of Power Supply Units where peared PAG COS SOS E ice res wreess as eccewnsanso EEA A E FON TRAI deena E then deansedsavdstasciedadatae A E EE Power Ral UPR O5 cree i RE ARRE EEN E E RAEE DER Mounting the UPR 05 Power Rail svecceutecussius ccceenctnnsscanassouebeods euensatieae Sotncee aea a aeeie e naoa aoaea idine Accessories for Power Rail UPR 5 sicscccercwssnicactovereentensisadiautaadta sinideieituiielibekosuchonetiotebhnwunsiGwrceigetnnd ofebdeoebinncebonabias POW EA ARAL T AOD i
187. esigned as intrinsically safe equipment Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 29 3 2 5 3 2 6 30 System Availability Internal RPI bus External standard bus Fault finding Replacement of defec tive devices Remote Process Interface Product Description Standard redundant design of the internal bus The bus signals are transferred between the two bus lines of the Power Rail as voltage difference signals If this transfer route fails due to lead breakage or short circuit between the two bus lines or due to a defective coupler the system switches automati cally to common mode operation in which the negative potential of the sup ply voltage provides a reference Redundant design due to the use of a second gateway The configuration data and parameters of the RPI system are also stored in non volatile memory in the redundant gateway Error messages via LEDs on the front panel of all devices Extensive possibilities for diagnosis via the configuration interface on the gateway with PACTware Edition 2 and Device Type Manager DTM for the RPI system Transfer of all error and status messages to the control system via the external standard bus system Thus it is possible to reduce the time required for locating faults and equip ment defects to a minimum A de
188. ess Signed integer 3 RPI address 3 5641 Floating point 5 RPI address 3 7567 3 registers have to be read in the signed integer format The data is constructed as follows Register address 1 Register address Channel 1 Status Channel 2 Status Channel 1 Register address 2 Channel 2 5 registers have to be read in the floating point format These are constructed as follows Register address 1 Register address Channel 1 Data word 1 Status Channel 2 Status Channel 1 Register addresst3 Register addresst 2 Channel 2 Data word 1 Channel 1 Data word 2 Register address 4 Channel 2 Data word 2 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Reading analogue input data 3 channel devices All the measured values from 1 2 or 3 channelled devices are represented in this area as a function of the current RPI address The register addresses can be obtained from the following equations Data format Register address Signed integer 6 RPI address 3 2072 Floating point 8 RPI address 3 536 If all the information from a device is to be read in signed integer format 6 registers have to be read Access to one ch
189. ess RPI address 1126 The data is structured as follows High byte Low byte Status Channel 2 Status Channel 1 The meaning of the individual bits is given in Section 7 3 10 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Reading binary inputs with status This information is deposited in register table 3 for up to 4 channelled devices The register address can be obtained from the following equation Register address 2 RPI address 3 2751 The data is constructed as follows Register address 1 Register address Data byte 4 Data byte 3 Data byte 2 Data byte 1 The meaning of the individual bits is given in Section 7 3 6 Writing reading binary outputs with status This information is deposited in register table 3 for up to 4 channelled devices The register address can be obtained from the following equation Register address 2 RPI address 3 2501 The data is constructed as follows Register address 1 Register address Data byte 4 Data byte 3 Data byte 2 Data byte 1 The meaning of the individual bits is given in Section 7 3 6 It should be noted that the status bits cannot be written 7 3 14 Configuring an RPI System via t
190. eter assignments to an RPI device For information on the type of multi channel devices available please refer to Chapter 4 1 7 Establishing the Miscellaneous and Monitoring Functions for the Operation 6 List of all RPI modules required with the full type code and if available with the corresponding measu ring point description The planning can be developed as usual by measuring station numbers since these can be transferred to the RPI and used in further working steps After having defined the basic functions and device types mentioned above you can already start planning configuring and programming the RPI system offline on your PC using the PACT are human machine in terface For the rare case that specific functions are not supported by the RPI devices from other systems can be linked by the RPI The Pepperl Fuchs team will be happy to provide appropriate solutions 4 1 7 Establishing the Miscellaneous and Monitoring Functions for the Operation In addition to the basic functions described in the chapter above the RPI devices also support a series of miscellaneous functions which can be activated and set The miscellaneous functions available are listed in Table 4 2 on page 38 It must be decided which of these messages are to be displayed or processed in the control system and which are merely required to be seen on the RPI human machine interface O Detailed information on the setting of these parameters and the various register
191. etization interlace Address 0 l Help Close Figure 6 8 Parameterizing the ControlNet gateway The Password Panel tab enables you to lock the operating unit and to activate the passwords by checking the respective boxes Isolated Switch Amplifier The Parameter tab contains both device specific and channel specific parameters 5 x Device adess Address 4 r Channel 1 Channel 2 Channel 3 Channel 4 lt 004 gt KSD2 BI EX4 Parameter Tag data ee Ta name P Sensor i Lead breakage detection Short circuit detection M Output Invert signal Filter time o0 Mal function output status logic zero Me Help Figure 6 9 Parameterizing KSD2 BI The entered address must be identical with the address set on the relevant device Device Address Tag Data Tag Name A description with a maximum of 32 characters can be entered into the box in order to ensure rapid and secure allocation Sensor Lead breakage detection The sensor lead is monitored for lead breakage Short circuit detection The sensor lead is monitored for short circuits Output Invert Signal The input signal is inverted and transferred to the bus Filter Time Filter time signifies that input pulses shorter than the filter time are suppressed By means of the settings Downscaled Upscaled or Hold Last Value the signal transferred to the control system in the err
192. eway it is necessary to determine the structure of a service level simultaneously The KSD2 GW gateways have an RS 232 or an RS 485 service interface The RS 485 interface allows up to 31 gateways to be networked with a PC It is possible to wire a point to point connection between a ga teway and a PC via the RS 232 interface or to connect a notebook directly to a gateway by means of a 3 5 mm jack The KSD2 GW2 PRO gateway has both types of interfaces It is also possible to carry out a configuration and parameter assignment via PROFIBUS DP or PROFIBUS DP V1 Further information can be found in Chapter 7 2 2 Gateway KSD GW2 PRO and Chapter 7 2 8 GSD Files Establishing the Measuring Ranges Basic and Miscellaneous Functions Now that the sensors and actuators are known the details are defined for each sensor field device and actuator The general data structure of the RPI devices can be entered or read out by means of a configu ration tool e g PACT ware Edition 2 or by way of the control system via the gateway Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Planning of the RPI System The data structure of each RPI device occupies the following areas e P
193. f gateways The RPI system is suitable for processing I O signals from a safe area or from a zone 1 or 0 hazardous area The signals are galvanically isolated using RPI Safe Area or Ex zone 2 Safe PLC Control System sensor signals actuator signals standard signals TE POQ SIA Power Rail with internal bus a HEA Besi oT SS Voltage Standard Bus supply e PROFIBUS e Modbus e ControlNet Hazardous area ald HE Kor 7 H Se D gt E Eo DH I 0 mM Remote Process Interface RPI Figure 3 1 Structure of the Remote Process Interface RPI Modularity of the RPI System A decided advantage of the RPI system is the high flexibility due to its modular structure The DIN rail with Power Rail represents the basis of the RPI The devices gateways and power feed modules or power sup ply units are mounted on the DIN rail Voltage supply and communication are established via the Power Rail The DIN rail and the Power Rail can be mounted according to the prevailing conditions and cut to any required length RPI devices with up to four signal channels are available for characteristic MSR technical tasks See chapter 3 3 Summary of RPI Modules Currently Available Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww peppe
194. f the PROFIBUS DP User Diagnosis for the RPI System Prerequisite No module 0 access Diagnosis Bhs Z module number GAT 1 BLB O ee 64 e O 5 N 0 NI O O max 13 faulty modules O It should be noted that an indication of the faulty PROFIBUS DP data module is not synony il mous with the RPI internal address of the faulty RPI module This applies especially to the case where packed modules are used Note The channel diagnosis is only transmitted when a channel error occurs Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface 7 3 KSD2 GW MOD and KSD2 GW MOD 485 Gateways for the Modbus RTU Gateways KSD2 GW MOD and KSD2 GW MOD 485 support the command and reply telegram according to MODICON Modbus protocol Reference Guide PI MBUS 300 Rev D The gateway incorporates a serial RS 232 or RS 485 parameterization interface optionally The operating level consists of an 3 1 2 digit LC display and of the three pushbuttons Mode Up and Down hh al i LED red mee i ioraa a Communication LED green _ Power LED red Internal communication LG Display CHE WNT ADR EXT LED yellow red
195. f the RPI System 4 10 Arrangement of the Power Rail Segments in a Control Cabinet The mounting rails with integrated Power Rails can be installed horizontally or vertically in the control cabi net A power supply module is required for each rail segment In the case of vertical mounting of the rails the length of the rail is in general greater than for a horizontal installation So that usually less power supply modules are required
196. f the RS 232 RS 485 interface Cycle time 3 2 4 Electrical Safety Wiring Fusing EMC Ex Protection Subject to reasonable modifications due to technical advances 250 kbit s Dependent on the bus system used See chapter 7 Integration into the Higher Level Bus System Adjustable 1 2 kbit s 2 4 kbit s 4 8 kbit s 9 6 kbit s 19 2 kbit s 28 8 kbit s 33 6 kbit s 38 4 kbit s 57 6 kbit s From the gateway via the external bus to the control system depending on the bus system used and its baud rate see Chapter 4 Planning From the device via the internal bus to the gateway or the reverse 1 Device 25 ms 125 Devices with up to 4 binary inputs 60 ms 125 Devices with up to 2 binary outputs 90 ms 125 Devices with 1 analogue input 75 ms 125 Devices with 1 analogue output 110 ms Please refer to Chapter 4 4 Calculating the RPI Cycle Time for the pre cise calculation of the cycle time The significantly reduced amount of wiring by comparison with conventional systems results in a corresponding reduction in the probability of wiring faults Group fusing via a fuse in the power feed module Tripping of the fuse is indicated by an LED and can be communicated to the control system via a relay output All RPI devices satisfy the requirements of DIN EN 50 081 2 DIN EN 50082 2 NAMUR NE 21 All devices identified by Ex in the type code have circuits which are appro ved for use in the hazardous area and are d
197. face whereas the KSD2 GW MPL 485 gateway has an RS 485 interface The operating level consists of an LC display with 3 1 2 digits and the three buttons Mode Up and Down External communication LC Displa status External address LED green Power LED red 7 yy Communication jee LED red Internal communication LED yellow red External bus Mode button pee IOR xx Seciece cee ceee 3 5 mm jack bush F z Button U 5 Button Down Figure 7 4 KSD2 GW MPL gateway Features of KSD2 GW MPL KSD GW MPL 485 Gateways The KSD2 GW MPL and KSD GW MPL 485 gateway connects the RPI internal bus to the external MOD BUS Plus The gateway thus assumes the master function for the internal bus The gateway has the function of a slave device on the external Modbus Plus To increase system availability the gateway and the external bus can be implemented in a redundant configuration The transmission rate of the Modbus Plus bus is 1 Mbps Megabit per second Device Connection The electrical connection of the KSD2 GW MPL Modbus gateways by means of cables with 9 pin Sub D connectors merely involves establishing the Modbus Plus connection The Modbus interface is an RS 485 interface on which up to 64 stations can be operated The parameterization interface can be either an RS232 KSD2 GW MPL or an RS485 interface KSD2 GW MPL 485 it is used to configure the RPI
198. face is used for the parameterization the two gate ways must be assigned two different addresses 4 Address and baud rate setting on the gateway parameterizing interface As described above using the pushbuttons set the addresses Mode E and the baud rates Mode G for the parameterizing interfaces on both gateways Take care that the addresses are different if the RS 485 parameterizing interfaces are linked together 5 Commissioning Mount both gateways and set the RPI system into operation as usual with the priority gateway Con nect the system to your PC and save your configuration data in this gateway via Download Now install the non priority gateway connect it to your PC and then save your configuration data in this gateway via Download If the E81 error message now appears on the gateway displays then the priority gateway has not yet been detected This error is eliminated by briefly interrupting the power supply Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 191 11 192 Remote Process Interface RPI System Error Messages RPI System Error Messages Error Messages on the Display of the KSD2 GW Gateway Error Code Meaning 01 A device included in the gateway configuration does not exist as a
199. fective RPI module is simply replaced with one of similar type Due to the removable terminal blocks there is no need to unfix any cable glands When replacing a device the device address and the device parameters are automatically transferred by the gateway to the new module When replacing a gateway the complete parameter and configuration data set is transferred automatically to the new gateway via the service interface Configuration and Parameter Assignment Device addresses Device parameters and RPI configuration data Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com The address of the RPI system on the external bus is set on the gateway The addresses of the devices and gateways on the RPI internal bus can be set via keys and the LCD display of the gateway via PC and configuration software or via the external bus Using the PC and PACT ware human machine interface or by the control system via the external bus The DTM can be integrated into every configu ration tool that supports the FDT Field Device Tool technology Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 3 3 Summary of RPI Modules Currently Available Currently devices are available within the RPI system for all instrumentation control and monit
200. g between the RS485 service interface and the PC 3 Inthe case of PROFIBUS DP V1 gateway KSD2 GW2 PRO it is possible to integrate the PC as class 2 master into the PROFIBUS and to transfer the data directly to the gateway via the bus The red LEDs of both RPI devices and gateways extinguish after the project data has been transferred to the gateway and as soon as the configuration is identical with the transferred parameter data and all field devices are connected to the RPI system correctly The External bus fault LED may continue to flash on the gateway if the bus master is not yet active If a redundant gateway is used the data must also be transferred to the second gateway as stated above Usually on downloading the parameterization data the commissioning of the RPI system ends since the integration into the higher level bus system is carried out using process control technique The information required for this procedure is given in Chapter 7 Integration into the Higher Level Bus System Verification of the RPI system can also be carried out without a higher level bus system Information on the various options is provided in Chapter Monitoring Simulating Measured Values and Error Handling Commissioning the Gateways and the External Bus System The commissioning procedure strongly depends on the bus system used e g PROFIBUS DP MODBUS RTU MODBUS Plus or ControlNet as well as on the control system used O Important i
201. g the KFA6 STR 1 24 4 power supply unit a redundancy of the power supply is not il possible Note Accessories Power Rail Power Rail is a DIN rail system in which five conductors are integrated providing for power supply and the Internal bus connection Power Rail is available in 2 different versions e UPR 05 with integrated mounting rail and variable device position e PR 05 as component insert for standard top hat rails device position predefined by grids AN The nominal current for the conductors integrated in the Power Rail is 4 A This current must not be exceeded Attention Only the UPR 05 Power Rail should be used for rewiring Power Rail UPR 05 Delivery package see Figure Figure 4 7 e Aluminium mounting rail 15 mm deep 2 m long e Power Rail insert with 5 conductors 2 m long can simply be cut to length e Cover providing mechanical and electical protection of free plug in stations e 2 End caps The UPR 05 has no mounting grid Thus components of any width can be mounted on this rail This is to ensure that the rail may be cut to any length and that the devices of future generations can also be mounted Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Pr
202. ght Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 e Internet http Avww pepperl fuchs com 165 7 4 3 7 4 4 7 4 5 166 Remote Process Interface Bus termination d active Rotary switch S1 for bus termination on the Bus termination 0 right side of the device not active Actuating by means S1 of a screw driver Figure 7 5 Rotary switch S1 for bus termination The Modbus gateways operate internally via a switchable bus termination Using a screwdriver the bus ter mination can be activated on the rotary switch S1 on the right side of the housing as viewed from the front This is used if the gateway is installed at the end of a line Modbus Plus address The address is set by the 6 dip switches on the front of the gateway marked NODE ADD Possible Modbus Plus addresses are 1 through 64 The coding of the DIP switches is indicated on the housing side A switch in the down or ON position is a logic 0 and conversely a switch in the up or OFF position is a logic 1 O The number of stations on one RS485 interface Modbus interface such as the RS 485 service il interface is a maximum of 31 as standard Note Commissioning Before commissioning check once again that all the connections are correct Familiarise yourself with the method of communication between the Modbus Plus master and the gateway Commissioning requires a know
203. gnal can be assigned a physical unit Voltage Range The zero point of the input signal is defined by selecting the volta ge range Lead fault detection The sensor lead is monitored for lead breakage Limit Values Warning limits active If you check the left box by clicking into it you activate the warning limits Now Lower Limit and Upper Limit turn from grey to black The limit values are entered into the boxes on the right hand side Alarm limits active If you check the left box by clicking into it you activate the alarm limits Now Lower Limit Upper Limit and Hysteresis turn from grey to black The limit values are entered into the bo xes on the right hand side Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 106 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 6 3 10 Measuring Range Start End Output Invert Signal Malfunction Output Status Analogue Driver Repeater Remote Process Interface Parameter Assignment The start value needs to be entered in order to be able to scale the measured value The end value needs to be entered in order to be able to scale the measured value The input signal is inverted and transferred to the bus By means of the settings As Input Minimum Maximumor Hold Last Value the
204. gnment of the RPI system depends on the RPI devices to be used and is explained in Chapter 4 1 5 Esta blishing the Measuring Ranges Basic and Miscellaneous Functions Safety related signals AN You should begin the planning process by clarifying which signals are safety related and which national specifications are applicable Attention Topology The structure of the plant and the spacial conditions determine the subsequent layout of the RPI system You should determine whether to accommodate the system in a control room or split it up and arrange it at different sites or in the field Splitting it into several systems enables larger applications to be divided into logical functional units and reduces the amount of wiring as the individual systems can be positioned closer to each field device HART Communication The application of HART compatible field devices has to be taken into account when selecting the RPI de vices and the gateway Suitable RPI devices have to be used for the transmission of the HART protocol Detailed information on various ways to transfer the protocol is provided in Chapter 4 2 Planning the Transmission of HART Protocols Fieldbus and Subordinate Service Level The fieldbus used is a decisive factor in selecting the gateways to be employed The RPI system can be integrated into the following fieldbusses e PROFIBUS DP e PROFIBUS DP V1 e MODBUS RTU e MODBUS Plus e ControlNet When selecting a gat
205. gurations of the RPI Devices cccceccccceeececeeeeeceeeeecaeeeesaeeeeseueeseueeesseeesseeeessanees 78 Error Messages in the LC Displays of the Gateways cccccssssccccsseeeeeeeeeeeeeceeeeeeeceeaeeeeaeaaeeeeseaeseeesaageeeessaneeeneas 79 Operating the Gateways of Type KSD2 GW2 0 ccccccccccecceaeaseeeceseeeeeeceaeeeeeeseanseeeeaeeaeseatasesessassstsessssessees OO Normal Operation Rum MenU csccesccouiacascsceuisactscescetaasgenesuagnsabes cuadaanuaseudsaetecaeddeavacsadaunedstesnetebasewiaaBordeueieseeteastoeaws 80 HART Communication HART Menu l cccceccceccceeeceeeeeeeeeeeceeeceeceuneceeeeseeeneeeaeeuseeeeeeeseseneeeaeeueeeneeeeeenestaeeees 81 E U i E steed eons acest doudraietees aces vee bouebioccenmeagiuecenecoiveceeaceunse 82 Indication of Measured Values Monitor Menu ccccceccecccecceeeeeeeeeeeeeeeeeseeeuceeeeeegeeeeeeeeeenseeeaeeeeeeeneeeseaneeaees 82 CHECKING THE DEVICE ADDRESSES ON THE INTERNAL BUS ssccssecnneenncecnnsnnnsencecnssnnesensecussenssensecuesensseuseauesenenenseses 83 Error INC See aces ees deces ree ates oe eE E queso eiemecieemadeceanesuasackeactoseedecne EE EEan 84 Input of Configuration Data Service MeN sccccccceeeeceeeeeeeeceeeeeeeeeeseeeeaaeeeesseeeeessaaeeeessaneeeessseeeessaneeenens 84 General Information on Input of Parameters And Values cccccccccseeeeeeceeseeeeeeeeeeeeneeeeeeceaeeeessaaeeeeeseneeeesaaaes 85 Teaching In the RPI Configuration
206. he Host It is possible to configure an RPI system via the host PLC or control system and to read the current con figuration In so doing the following information must be transmitted to the gateway read e Device ID e Device type e Parameter values for each device measuring range with or without lead breakage short circuit monitoring etc The following table shows the relationship between RPI device device ID and device type Device Device type KSD2 GW MOD Z 03h 05 oh OAh OE Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 159 Remote Process Interface The device ID and the device type is stored as a function of the RPI address The register addresses are obtained as follows Device ID Register address RPI address 4096 Device type Register address RPI address 4224 The parameter values can be accessed or written to via an acyclic channel These values are then ex changed via 2 mailboxes host RPI or RPI host Further information on this functional procedure can be obtained directly from Pepperl Fuchs 7 3 15 Diagnosis Channel based diagnosis can be supported by read out of the corresponding status information In addition to this information register table 4 provides device based data Register address RPI add
207. he following submenus can be selected using the Up and Down buttons e Support Activates the HART support Settings On Off e RebldSingleLp Individual HART loops can be built up Settings 0 to 255 e RebAllLps All connected HART loops are rebuilt This process can be extremely time consuming de pending on the application e PerfMode This is where the operating mode for the HART support can be determined with regard to the details of the HART standard nor Normal mode secondary master and Burst mode are permitted FASt Only Burst mode permitted HI Neither Burst mode nor secondary master are permitted e LongFrAddr The Long Frame Address can be uploaded here Display Byte 1 byte 5 Resetting Internal Communication ResIntCom Service Menu This menu enables a synchronization procedure to be initiated on the internal bus in order to allow the sy stem to change from redundant operation to normal operation The procedure is initated using the key com bination which is also used to save parameters Switching Back from Redundant Operation SetActiveMode Service Menu This command relates to the external gateway redundancy If the system is in redundant operation and if the priority gateway is available again the latter is reactivated by means of this function In this case the same functions as inthe ResIntCom and Teachlin menus are performed Information on Hardware and Software Versions Info Serv
208. he project on the data carrier not in the individual RPI devices Note Editing a Project A project in PAC Tware presents the structure of your RPI system By means of the connection of your field devices to the RPI interface modules the allocation of the field devices to both the RPI gateways and the corresponding address on the external bus is documented The same applies to the underlaying service network provided that the RS 485 service interfaces of your gateways have been wired The project is configured using the various Device Type Managers DTM DTMs for devices of other ma nufacturers can be used apart from the DTMs offered by Pepperl Fuchs as long as they conform to the FDT Field Device Tool standard A typical project is structured as follows B PACT ware hn e J Fie Edt View Device Extras Windows Help sga eee W EG HOST PC 34 lt COM1 gt API Serial Interface i lt 001 001 gt KS02 GW PRO 495 im lt 003 gt KSD2 C1 S EXH aby lt 004 p KSDZBIEX E 23 005 gt KSD2 B0 EX2 2 lt 001 00 gt KS02 Gw PRO_485 gy lt 003p KSD2 01 S EXH my 004 KSD2 BI EX4 Ta lt 005p KSD2 00 5 EXH 006p KSD2 80 EX22 e lt 007 KSD2 TI EX El com KE 300 lt COM1 gt KFD2 GU EXI 7 fe Rimana Pw ee start 1 O E kaender Mictoso 2A venus E Windows Comman T PACTware H Unbensnnt Paint DSR 1247 Figure 6 1 Projekt structure Subject to reasonable modifica
209. hese persons need an appropriate instruction by the operating authority of the plant Attention Apart from this handbook the relevant guidelines for the installation in hazardous areas should be observed The individual chapters of this handbook are aimed at persons with different qualifications as listed below Chapter Target Group Qualifications Chapter 1 Planners personnel undertaking commission ing process control engineers service per sonnel Chapter 2 Planners personnel undertaking commission ing process control engineers service per sonnel Chapter 3 Planners personnel undertaking commission ing process control engineers service per sonnel Chapter 4 Planners personnel undertaking commission ing process control engineers Broad knowlege of RPI installation in hazar dous areas overvoltage protection and know ledge of the bus system Chapter 5 Personnel undertaking commissioning pro cess control engineers Broad knowlege of RPI knowledge of the human machine interface Chapter 6 Personnel undertaking commissioning pro cess control engineers Broad knowlege of RPI knowledge of the human machine interface Chapter 7 1 Process control engineers Chapter 7 2 Process control engineers PROFIBUS DP and DP V1 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore
210. iagnosis can be trans mitted in addition to the status information These diagnosis messages allow a rapid error localization The diagnostic information consists of a standard diagnostic information byte 1 to byte 6 and an extended DP slave specific diagnostic information The start of the gateway specific diagnostic data is identified by a header byte Byte 7 Gateway Diagnostic Header MSB LSB ino7 6 5 4 3 2 1 o Byte 8 Gateway Status Block length header byte incl in byte Fixed on 00 MSB LSB seve eee E2PROM_ERR APPL_ERR WATCHDOG TIMEOUT _KOM COM MODE LOCAL_ACCESS Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com E PROM_ERR APPL_ERR WATCHDOG TIMEOUT_KOM COM_MODE LOCAL_ACCESS Reserved 1 error in EZ2PROM 0 no error 1 internal interface error 0 no error 1 one or more RPI modules have gone into the safe condition follo wing expiry of the watchdog timer 0 no error 1 one or more RPI modules with output channels were not addres sed by the gateway within the agreed time out period or one or more RPI modules with input channels have not sent their data to the gateway within the agreed time out period 0 no error 1 one or more RPI modules have changed over from difference mode to common mode operation for commu
211. iate HART compatible RPI devices The programming unit is connected to the non Ex terminals of the RPI module The protocol is transmitted via a hand held device or a PC which is connected to the terminals of the RPI device thus enabling direct communication with the field device O The HART and SMART compatible RPI devices KSD2 Cl S Ex KSD2 Cl S Ex2 H il KSD2 CO S Ex and KSD2 CO S Ex2 H are equipped as standard with KF STP BU KF STP GN oe terminal blocks Chapter 4 10 5 Accessories for the connection of the HART handheld device 4 2 2 Connection to the HART Multiplexer HART mulitplexer and HART Control module Signals of several HART compatible field devices can be collected and transmitted simultaneously via the KFD2 HMM16 HART multiplexer The HART signals of the field devices are transmitted to rail 4 of the Power Rail by means of HART compatible RPI devices This railis read out by the KSD2 HC HART Control module and the data is transferred to the HART multiplexer via a 14 core flat cable The HART programming unit or a PC with an appropriate HART software can be connected to the HART multiplexer Further details can be found in the product description of the KFD2 HMM 16 HART multiplexer master O il The power feed modules KFD2 EB RPI or KFD2 EB R2A RPI must be used Note For transmitting the protocol the Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fu
212. ic communication processes PC programs and PROFIBUS PC plug in cards are available to enable the communication rela tionships and their parameters to be specified and to allow bus telegrams to be displayed on the screen in an understandable manner The system software provided with PLCs and process control systems that use PROFIBUS communications processors often provides appropriate network configuration and management facilities The most important features of the gateway with respect to PROFIBUS DP are Modular DP slave i e the gateway represents the RPI devices on PROFIBUS according to the RPI in ternal hardware structure lt 64 RPI devices for more than 64 RPI devices several identical devices will be represented in one module Full DP slave functionality with the functions Data_Exchange RD_Inp RD _Outp Slave_Diag Set_Prm Chk_Cfg Get_Cfg Global Control Set_Slave_Add Self synchronising transmission rates between 9 6 and 1500 kbit s Switchable bus termination PROFIBUS device addresses 1 125 are available Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 127 7 2 11 128 Remote Process Interface Gateway Specific Diagnostic Information During data transmission diagnostic data for a station module and channel based d
213. ice A can then be returned to operation by simply snapping it onto the rail again Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Quick instructions 1 In order to avoid such conflicts new devices are factory set to the address 0 As described in Section 10 7 Setting Address 0 Deleting Address on a Device you can also assign the address 0 yourself 2 To check the addresses of devices You can check the addresses of devices Press the Mode button repeatedly until C Check internal address appears in the right hand position on the gateway display The number to the left of the sym bol represents a device address Using the or buttons on the gateway select the desired address Only those addresses are displayed which have actually been assigned within the system The green PWR LED flashes on the device to which the selected address belongs Conversely you can determine the address of a particular device in operating mode C of the gate way Press the ADR button briefly on the device The green PWR LED flashes on the device the address of the device appears on the gateway display 3 Toteach the bus structure into the g
214. ice Menu The version of the gateway is indicated in this menu 1 SWRem Software version internal bus 2 SWHst Software version PROFIBUS 3 HWVer Gateway hardware version Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Configuring and Commissioning the RPI System 5 5 Verification of Device Addresses 5 5 1 Checking the Device Address on the RPI Internal Bus 5 5 1 1 Checking by Means of KSD2 GW Gateway On selecting the operating mode C CHK INT there are two principal ways of checking the address of a device 1 By ascertaining the device that has the address that is indicated on the gateway display Cycle through the addresses on the gateway display using the WY and 4 buttons Only those addres ses are displayed which are actually present on the internal bus The green PWR LED flashes on the device whose address is shown on the gateway display 2 By determining and displaying the address which is held by a particular device Briefly depress the ADR button less than 3 s on the device that is to be identified The gateway display shows the address of the device On the device itself the green PWR LED flas hes 5 5 1 2 Checking by Means of KSD2 GW2
215. ices and the gateway will be accep ted into your PC If you respond with No all the devices will be assigned the default values Do not accept the device data entries into the new project You can always change these values at any later point in time Depending on the version of your human machine interface the question appears if the device data files should be accepted You respond Yes for all The connection has now been successfully established Faulty connection see Appendix Error Messages Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Quick instructions 14 Parameterizing devices Now set up the data for the individual devices In the left window of the main menu of the human ma chine interface click on a device that is to be configured and select Device data Edit device data A dialogue window opens with tabs having white fields into which the data can be entered Write the data into the device with Device Save to device On closing the device data window save the data in a file The file name can be freely selected but the file name extension must always be dat Depending on the device type used different tabs are opened for parameterizing the devices Detailed information is given in appendix B about PACTyare 15 Store the project Save the data for your RPI system on your PC using Project Projec
216. ices the changed settings must be downloaded twice for the COM driver and for the device separately 8 Parameterizing the COM port In order to parameterize the COM port the COM port on the PC notebook and the baud rate of the serial interface should be set in the tab 9 Parameterizing gateways In order to parameterize the gateways the address of the gateways the baud rate and the parity stop bit should be entered You enter the data into the white fields of the dialogue window tabs Two code words can be used to provide protected access Each of these ensures full access to the system Always assign both code words If one code word is left blank it increases the risk of access by unauthorised persons If you click on Panel locked you will not be able to make changes later with the gateway buttons Therefore this option should not be marked in the check box at this stage In order to be able to link the parameterization interfaces together assign an address This address must be assigned even in the case of simple point to point RS 232 connections In the diagram it appears in pointed brackets lt 0 gt The selected address must correspond with that set later on the gateway When this window is closed the gateway data should be stored in a file offline or in the device online as when parameterising the COM ports Any names can be used for the files but the file extension is always dat 10 Parameterizing R
217. ich are not available is set to 0 7 3 7 Writing Reading Binary Output Data without Status Binary output data includes signals for valves operating coils of relays and optical and acoustic alarms The KSD2 GW MOD and KSD2 GW MOD 485 provide this data both channel based and device based In the channel based form of representation each channel of a device is represented in an individual register This type of representation is to be preferred if only 1 channel is to be read or written to In the case of the device based form of representation up to 4 RPI devices can be represented in one register This form of representation enables the data of many RPI devices to be transmitted with relatively small amounts of data O The prerequisite for this is that the RPI addresses of the devices are consecutive Note Further information on the relationship between RPI address and data range can be obtained from the cor responding topics in this section Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 143 144 Remote Process Interface Register addresses for channel based registers Writing reading a channel This data is deposited in register table 1 The current states can be read via function code 01 and written to with function code 05 Th
218. ide The start value needs to be entered in order to be able to scale the measured value The end value needs to be entered in order to be able to scale the measured value Copyright Pepperl Fuchs Printed in Germany 105 Remote Process Interface Parameter Assignment Output Invert Signal The input signal is inverted and transferred to the bus Malfunction Output Status By means of the settings As Input Minimum Maximumor Last Value the signal transferred to the control system in the error case is determined according to the application For the set ting As Input a value should be entered in the box on the right hand side 6 3 9 Converter for Voltage The Parameter tab contains both device specific and channel specific parameters lt 006 gt KSD2 BO EX2 2 Parameter _ loj J Device address Address E 6 Charnel 1 Channel 2 Tag data Tas name Senso Lead breakage detection J Short circuit detection Output Invert signal Mal function output status logic zero Help Figure 6 15 Parameterizing KSD2 VI Device Address The entered address must be identical with the address set on the relevant device Tag Data Tag Name It allows you to type in a descriptor tag name which may contain up to 32 characters This is helpful for larger projects to identify the devices clearly Sensor Unit In this box the input si
219. iderably enhanced by this device Order code KFDO LGH for the connection of intrinsically safe circuits 7 8 9 12 11 10 for the connection of safe area circuits Figure 4 15 KFDO LGH Dummy module Various wiring layouts are possible by using soldering jumpers and optional DIP switches Intrinsically safe circuits up to 40 V can be connected to terminals 1 2 and 3 or 4 5 and 6 Non intrinsically safe circuits up to 50 V can be connected to terminals 7 8 and 9 or 10 11 and 12 O il Terminals 1 to 6 are to be considered connected Note Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 59 4 9 60 Remote Process Interface Planning of the RPI System Determining the Types and Numbers of Power Rails to be Used Having determined the types of Power Rails to be used e PR 05 length of the rail 500 mm or e UPR 05 length of the rail 2000 mm the number of rails required can be calculated based on the number of RPI modules and power supply seg ments determined in the previous chapters It must be noted that approx 1 mm or more separation is required between the Power Rails if two power supply segments are to be built on a common mounting rail The following calculation determines the space required for the RPI system for both simple
220. il the LC display flashes Later on this baud rate must agree with the COM port setting of the RPI human machine interface Baud rate codes ae 1 2 kbit s pis 2 4 kbit s A 4 8 kbit s 9 9 6 kbit s m 19 2 kbit s 28 28 8 kbit s 5 To set the gateway address for the external bus Mode D Now press the gateway Mode button repeatedly until d external address setting appears in the right hand position on the gateway display The adjacent number on the left is the code for the gateway baudrate for the external bus Select the desired value using the or buttons on the gateway The baud rate is accepted in the gateway by depressing the Mode button for a longer period 6 The addressing and the settings on the devices are now complete You should now connect your PC and establish the device parameters using the RPI human machine interface 7 Now connect the gateway parameterizing interface with your PC interface using the cable supplied If you are using a gateway with an RS232 parameterizing interface connect your PC either to the jack on the front or to the plug in screw terminals 7 8 and 9 of the gateway The front jack and the screw terminals for the RS 232 connection must not be used at the same time The gateway with the RS485 parameterization interface has only the plug in screw terminal connec tion Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany
221. in screw terminals 7 8 and 9 of the gateway The front jack and the screw terminals for the RS232 must not be used at the same time The gateway with the RS485 parameterization interface has only the plug in screw terminal connec tion 15 Gateway settings address and baud rate of the parameterizing interface To set the address and baud rate of the interface press the gateway Mode button repeatedly until E appears in the right hand space on the gateway display The number on the left is the address of the parameterizing interface f this does not agree with the entry in the pointed brackets lt 0 gt on the human machine interface select the correct address by operating the or pushbuttons on the gateway Now depress the Mode button until the gateway display flashes The address has now been accepted by the gateway Now press the gateway Mode button until G appears in the right hand position on the gateway dis play The number on the left is a code denoting the parameterizing interface baud rate If this does not agree with the data rate assigned to the COM port by the human machine interface select the correct setting by operating the or buttons on the gateway Finally depress the Mode button until the gateway display flashes The baud rate has now been accepted by the gateway Baud rate code digits T 1 2 kbit s P 2 4 kbit s 4 4 8 kbit s 9 9 6 kbit s 19 19 2 kbit s 28 28 8 kbit s 16 Download On the hum
222. ing point format 6 registers have to be read per device The data is constructed as follows Channel 1 Register address 1 Register address Channel 2 Register addresst3 Register address 2 Channel 3 Register addresst5 Register address 4 Data byte 4 Data byte 3 Data byte 2 Data byte 1 Data for unoccupied channels is set to 0 7 3 12 Writing Reading Analogue Output Data with Status Reference should be made to Chapter 7 1 of this handbook for the structure of the status information Writing reading analogue input data 1 channel devices All measured values from 1 channelled devices are represented in this area as a function of the current RPI address The register addresses can be obtained from the following equations Data format Register address Signed integer 2 RPI address 3 4742 Floating point 3 RPI address 3 6409 In the signed integer format 2 registers have to be read The data is constructed as follows Register address 1 Register address Status Channel 1 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 153 154 Remote Process Interface In the floating point format 3 registers have to be read These are constructed as follows Register address 1 Register address Data byte 2 Data by
223. input the unit constant allows a conversion from Hz to another physical unit e g rpm for rotatio nal speed m h for flow etc This is necessary when the higher level system requires other units than Hz The unit constant is de fined as follows Example At an input frequency of 100 Hz the output value is to be 20 This results in a unit constant of 5 Ata counter reading of 2500 the transferred value is to be 125 This leads to a unit con stant of 20 Enter value for Offset By means of the settings As Input or Hold Last Value the signal transferred to the control system in the error case is deter mined according to the application For the setting As inputa value should be entered in the box on the right hand side The Parameter tab contains both device specific and channel specific parameters lt 006 gt KSD2 BO EX2 2 Parameter E ioj xi Device address Address fe 7 Channel 1 Channel 2 Tag data Tas name Sensor Lead breakage detection Output Invert signal Mal function output status logic 2e 0 v Short circuit detection Help Figure 6 11 Parameterizing KSD2 BO Device Address Tag Data Tag Name Sensor Lead breakage detection Short circuit detection Output Invert Signal Malfunction Output Status Subject to reasonable modifications due to technical advances 102 Pepperl Fuchs Group Tel Germany
224. inputs device type device ID Force Single Coil Write binary outputs Preset Single Register Read from write read registers e g analogue outputs acyclic parameter channels Read Exception Status Read the exception status of the gateway 03 04 05 07 Read Diagnostic Service functions for Modbus Force Multiple Coils Block wise writing of binary outputs 16 Preset Multiple Registers Block wise writing of analogue outputs or acyclic parameter chan nels These function codes are part of the Modbus message The Modbus message also gives the register address of the first and the number of registers to be processed The following relationship between the transferred register address and the register to be processed should be noted The register address transferred in the message is always referenced from zero The register address 0 must be transferred in order to be able to access the first register that can be interrogated Register number Example In order to access register 26 in table 2 status of the binary input RPI address 3 channel 1 the function code 2 and the register address 25 must be transferred O1 _ O In the following description the register addresses to be transferred are given as a basis If il your software register numbers are to be used in processing the given register address 1 value must be used Note The equations used to calculate the register addresses and a description of how the da
225. interfaces have no jack Detailed information on the differences between ga teways for PROFIBUS Modbus RTU Modbus Plus and ControlNet is provided from Chapter 7 2 onwards Chapter 5 Configuring and Commissioning the RPI System provides an explanation of the RPI system configuration via the gateway pushbuttons and of the menu structure Construction of the devices LED red __ Communication LED green ____ Power supply LED red Internal communication hn LC Display LED yellow red ap tt External bus Button Up Button Down Mode button Rotary switch RS 232 termination resistor 3 5 mm Jack bush for PROFIBUS Figure 7 1 Front View of the KSD2 GW gateways Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 109 110 Gateways of Type KSD2 GW2 Remote Process Interface Integration into the Higher Level Bus System Gateways of type KSD2 GW2 have both RS232 and RS485 service interfaces a double row LC Display and four buttons for menu prompting The RS485 interface is connected via the terminals 7 8 and 9 whe reas the RS232 interface is designed as a 3 5 mm jack plug located on the front of the device Since both interfaces are independent they can be used simultaneously Detailed information is given in Chapter 7 2 Gateways f
226. ion Password Parel Hotes Display Panel Locked Passwords Password 1 46CD Password 2 CCEA x Passyord active 12 3 6 5 Saving data 12 3 7 12 3 8 12 3 9 210 lf you want to save the data to the device i select Device save to Device a use 4 v then s To save the data into a dat file 8 select Disk save to Disk a use 4 d then f s Enter a file name with up to 8 characters plus the extension dat and press OK The project file contains a list of all related data files If you do a download the project manager uses the data files to set the infor mation of the according devices Downloading a project into a gateway Use Project Project Download to download the present project configuration into the selected gate way If you use this option the gateway accepts this configuration as target configuration Any different hardware set up results in error messages To proceed with downloading confirm the following dialog box with yes After positive confirmation a connection to the gateway is established and the information proces sed The connection shuts down afterwards Printing a project Select Project Print to print the present project If you need to configure your printer or want to use a different than the standard use Options Printer Configuration first Monitoring devices You can monitor the output signals of all connected devices by selecting Display b
227. ith a maximum of 125 RPI devices addresses 003 to 127 6 2 4 Deleting Components Before you delete a device from the project tree make sure that you selected the correct device s There is no undo function available Attention There are two ways to delete a device from the project tree 1 Click onto the device that you wish to delete from the project tree using the right mouse button and select lt Delete Device gt 2 Click onto the device that you wish to delete from the project tree using the left mouse button and then onto the lt Delete gt button down on the left Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 96 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Parameter Assignment 6 3 Parameterizing Individual Components In order to edit an RPI device in PACTware 1 click onto the component that you wish to edit in the project tree using the right mouse button and sel ect Offline Parameter or 2 double click the component that you wish to edit in the project tree or 3 Click onto the component that you wish to edit in the project tree using the left mouse button and then click the Edit button in the project window down on the right or 4 click onto the component that you wish to edit in
228. its RPI Devices ME ENT HART Protocol Transmission HART Programming Unit With Direct Connection ccccccccssseeeeceeeeeeeeceeeeeeeseeseceeaaaeeeeessaeeeeeseseeesseeeeessaeeeeessaneeeeess Transmission via HART Multiplexer saces cctesexencceacentuacacainesnciencdenmnianusbnoaatnne AeasceBhesendansdeenadbmaateeuacbdaeeoiedebceeacctebsensdooues HART Transmission via PROFIBUS a snnnannnnnannnnoennnosnnnnrrnnrrornnrrrrnnrrrrnnrrernnrrernnrenrnnrenennterennrenranrenannrennnnrennnnrennnneennnnnene Performance Characteristics essssessasnunonununnannnnannnnnnnnanannnnennnnnnnnnuannnnnnnnnnnnnnnnnnnannnnannnnnnnnnnannnnnnnnnannnnnan Overview of the RPI System Characteristics cccccccccceceseeeeceeeeeeseeeeceeeceeaeseceeeacaeeeeseeeeaueseeeaaeseeaneeeasanees Flexibility by Virtue of Modularity 20 cee ccccesecesneececeeceeeneeeeceaaceeaeeaeeseaeeeeeeaeeeeaeeaeaeaeeeeeseaeeeeaeaeeaeaaeetaneeeeess Internal and external communication cccec cece eeceeee este eee eeeeeseeaaeececeeceeeeeeaaeeeeeeeaneegeeegeneeeeceeeeeeeeaneaeeeagees Electrical Safety System Availability EEES Configuration and Parameter Ae oime Summary of RPI Modules Currently Available c c cececeneseecceeeeeeeeeeeeeeensceeeeeeesensesnseeaeseseaesneeneeaes 230 V AC POWER SUPPLY UNITS ssssssossnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nnmnnn nananana nnna nnna 24 V DC POWER FEED MODULE
229. l Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 117 118 If the PF0818P GSD file is used Remote Process Interface e parameter assignment of the RPI devices is carried out via PROFIBUS However not all the functions of the RPI devices can be accessed For example scaling will no longer be possible for analogue inputs or outputs e Likewise packing modules will no longer be possible exception up to 4 temperature converters can be packed Defined Modules and Data Types Many different types of module are defined in the GSD files to allow all RPI devices to be clearly represented as DP slave modules The modules defined are oriented to the function of the RPI modules and differ according to e Type of data e Data format e Status information e Number of channels Number of RPI modules Examples Type of module 4DI_ STAT 1AO_FLOAT 4x2DO_S KSD2 BO Ex2 input data 1 output data O binary D analogue format signed integer A _INT analogue format FLOAT floating point A FLOAT with status information _S _ STAT without status information 1 8 1 8 nx Note packing the modules Explanation 1 RPI device with 4 channels binary input data with status information 1 RPI device with 1 channel analogue output data floating point data format without status information 4 RPI devices each with
230. lacement of the devices is sufficient Note Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 179 8 6 8 7 8 8 180 Remote Process Interface RPI in Operation If more than one device of a type has failed and it is desired that the ascending sequence of addresses is not maintained then the device addresses and parameter sets are loaded into the devices individually in a separate work area using a gateway via a PC and the PACT are human machine interface These new devices are then incorporated into the system by snapping them onto the rail O The devices must be allocated addresses in ascending order commencing with the lowest il address in the series Otherwise the automatic loading of the parameter sets does not function Note Error detection on the external bus system Depending on the bus system used the scope of error detection and device diagnosis are also very exten sive The way in which the error and diagnostic information are placed at the disposal of the user depends very much however on the master device used Reference should be made to the documentation for the bus system in use as provided by the manufactu rer O Detailed information for an evaluation of PROFIBUS DP PROFIBUS DP V1 MODBUS RTU il MODBUS PL
231. le 1 To find the address for an RPI device with RPI address 27 The division RPI address 3 4 gives 6 without a remainder Hence the register address is 6 9216 9222 The 4 channels are represented in the low nibble of the lower byte Example 2 To find the address for an RPI device with RPI address 37 The division RPI address 3 4 gives 8 5 or 8 with a remainder of 2 The address to be transferred is therefore given by 8 9216 9224 The remainder shows that channels 1 to 4 of this device are represented in the low nibble of the higher byte of this register Channels which are not available are set to 0 RPI devices with a maximum of 8 channels 2 devices per register All data from 1 2 4 or 8 channel devices are filed in this area The register address is obtained from the following equation Address Int RPI address 2 2 9345 Int denotes a whole number of rounded down The data is represented as follows RPI address 1 RPI address chi Cha It should be noted that fundamentally only even RPI addresses are represented in the lower byte of a re gister and odd RPI addresses in the higher byte Channels not available are set to 0 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 141 7 3 6 142
232. le of contents Analogue Driver Repeater c cccsssseeceseeeeeeeeeeeenes E EE EE E E E gt CURRENT FREQUENCY CONVERTERS BATCH CONTROLLERS FLOW METERS ssecncceccccencenseceansesenencnsnnenensnes OO TEMPERATURE CONVERTERS osvacouces iver visesetiensee atrecarc tit ccgaeeen saber E eds ettar te nanea Oe VOLTAGE CONVERTER sorisa rana AEREE EEE ces vnc ted eng nse popes ad coeeseceeieeene seat e TE WAYS sia restate ce tese scenes E E E EE E AE E ssi OS HART VOCUS S ssesee ct seem scenes ae se E be ve cence sens coos aac aye cee pas oo eisai be oa ee betas Sa esse eee desea OS Commissioning Procedure for the RPI System cccseeceeeeceseeneesceeeeneeeseseeeeenseeeesoeensaeeeneesssseassssases OO OAT LUM ACOA te eiccse ceca ec ae ce cence odecnctacssoaciesctss A A sa eososneeceeaeereeteets OG Parameter Assignment cccccceceneececeeceneeceeecesseesseeeeeseaesseeeeeceaeseseeeessaeesseseessaeeenesesessetenessastetianetssstess OO Integration into the Higher Level BUS System ccceccceececeaeeeeaeeeeeeeseeeeeeseeeesesaeseseeseesesesessneesatsnsssatsseees OO Control Cabinets Assembly and Service ccccccsccececeecesececeecesecnseaceseonaceseansnaseseseaesseanscassessescsssssscsses OF PLANNING COMMISSIONING CONFIGURATION AND PARAMETER ASSIGNMENT PLANNING OF THE RPI SYSTEM cscccecsccecscccnccccssacnsccensnencecenenenceeeneseecssaneseeeusasueessasceseessnss OD Planning Basics and Procedure sssassussnnsnnnn
233. ledge of the Modbus Plus and the parameter assignment of the Modbus Plus gateway Time response The Remote Process Interface is deterministic The RPI devices are interrogated cyclically The most important factors which determine the time response are e the higher level host system e g process control system PLC or PC e the type and number of Modbus Plus stations e the number of the RPI devices and the cycle time of the RPI system e the user program Data Transfer on the Modbus Plus Modbus Plus functions The Modbus Plus is a register orientated bus system This means that the data is automatically stored ina memory area the so called registers of the Modbus Plus gateways Modbus Plus supports the Modbus RTU functions which are listed in the table below The user can access specific data by reading the regi sters and set targeted outputs or interrogate diagnoses by writing to these registers 03 Read Holding Registers Reading write read registers e g analogue outputs acyclic parameter channels Preset Multiple Registers Block wise writing of analogue outputs or acyclic parameter chan nels Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 7 4 6 Remote Process Interface Data tra
234. ly on the device and on the gateway 5 5 2 2 Address Assignment by Means of KSD2 GW2 Gateway e Use the buttons of the gateway to select the Service menu as described in Chapter 5 4 3 on Page 80 e Select the service menu Address Assign e The address can be changed using the Up and Down buttons Only free addresses are displayed e The address is transferred to the RPI device by depressing the ADR pushbutton on the front panel of the device that is to be addressed for longer than 3 s e The green LED on the gateway flashes for a brief period and the gateway display shows the next free address Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 89 5 9 3 90 Remote Process Interface Configuring and Commissioning the RPI System Assignment of the Neutral Device Address 0 for the Internal Bus The address of an operational device can be reset to the neutral address 0 the setting on delivery by snap ping the device without a gateway on to a Power Rail with power supply and then depressing the ADR button of the device for longer than 3 s O The parameters of the device do not need to be deleted since they are automatically overwrit ten by the gateway when the device is used as replacement device Note Subject to rea
235. measttedt 99 ON ar N R E E tenn ascsatenwcese 99 Isolated Switch Amplifier ar Poise o castro cteeecieteaeass tea aewaeseaunesicaeee a a a WOU Current Frequency Converter Batch Controller 0 0 00 cccecccceeceeeeeeceeeeeeeeeeeaeeseeeeaeseeeeesasseesesssetseseesaseeeees 101 Solenoid DrIVErS seen eee ee ee Ree ere eee eee ee ee A Relay WC CNG Sr gosh sarccese ada ay ENE N a E Ees 1 OO Transmitter Power Supplies c ccccceecececeececesneseaueseeceseseeeesaeeeausseseaseeeeaeseeteaesssansstessstsesersessssssssssassess LOG Temperature Converter 20 cc cccececescececnecececuesecuseesceceseeceseeeeanseeessaeeeeaeseeeeanessaneatesasssessseesssssasesssesssssesseres OD Converter for VY ON AGS sears cts octets a naa a E EaR KARES Aa RAE EEn aeiae iie WOO Analogue Driver Repeater cccccscsseseceseeseecceaeeaeeeaeenseceeaeeaeeeeeeuaeesaesseeeeseneseseesesesesersesesesersesesesstecssesses OZ Downloading Project Data into the Gateway ccccceeeece cece ence ee eeneneeceeeneeseceaeeseseaeaeeseaeaeaeeaeanaesseaseees 1 OG Commissioning the Gateways and the External Bus System ssssnnsnsnnnnnnnnnnnnnnnnnnnnnnn nennu nn nnmnnn LOS INTEGRATION INTO THE HIGHER LEVEL BUS SYSTEM cccccccceceecnccecsccesacnccccsesaseencesesesasss 1 OQ General Notes on Operating the Gateways cccccssssssessceseseseeceeseeeensesceaneneesenseseansseensesnsasssesseassereees OQ Gateways Of Type KSD2 GW ooo cccccccccecececeecececeaesceces
236. mmunication Housing type B2 see system description LED green ___ Power supply LED red Communication LED red Internal communication LED green Power supply Button Bown LED yellow red External bus Rotary switch d termination resistor RS 232 for PROFIBUS 3 5 mm Jack bush Removable terminals RS 485 green Serviceinterface Remote Process Interface Planning of the RPI System mois Se Se i i Fn a F Fy ae a so i a Ja D LC Display Button ESC Button Up Button OK Button Down Rotary switch termination resistor for PROFIBUS l Removable terminals m green KSD2 GW2 PRO 4 5 2 4 5 2 1 4 5 2 2 Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com Figure 4 5 Front view of Gateway KSD2 GW PRO and KSD2 GW2 PRO More detailed information on the LEDs and the operation of the gateway can be obtained from Chapter 5 Configuring and Commissioning the RPI System The RPI system can be integrated into the following bus systems e PROFIBUS DP KSD2 GW PRO Gateway e PROFIBUS DP V1 KSD2 GW2 PRO Gateway e MODBUS RTU KSD2 GW MOD Gateway e MODBUS Plus KSD2 GW MPL Gateway e ControlNet KSD2 GW CN Gateway Please note that the gateways are available with RS232 or RS485 servi
237. n Address RPI address 1536 The data is represented as follows Oo o o o o oO Oo o0 chs Ch 1 Channels not available are set to O RPI devices with a maximum of 4 channels 4 devices per register All data from 1 2 and 4 channel devices are filed in this area The register address is obtained from the following equation Address Int RPI address 3 4 9216 Int signifies a whole number of rounded down Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface The data is represented as follows RPI address 3 RPI address 2 RPI address 1 RPI address cht Cha If the term RPI address 3 4 is divisible without a remainder then the data is that which is represented in the low nibble of the lower byte RPI address Ch 1 Ch 4 or bit 0 to bit 3 of the register If the division results in a remainder this remainder describes the nibble of the register in which the data is represen ted The following relationship applies Lower byte low nibble or bit O to bit 3 Lower byte high nibble or bit 4 to bit 7 Higher byte low nibble or bit 8 to bit 11 Higher byte high nibble or bit 2 to bit 15 x arbitrary digit before decimal point Examp
238. n T Warning limits active iT Alame limits active l fi T H Upper knmi Hz Measure range Unit constant 10 Hz Offset 10 0 Hz Output Mal furrction hold last value Y alue fi rz oulput status a Sani The entered address must be identical with the address set on the relevant device It allows you to type in a descriptor tag name which may contain up to 32 characters This is helpful for larger projects to identify the devices clearly In this box the input signal can be assigned a physical unit Four different operating modes can be selected Frequency input withorwithout rotation direction monito ring counter input withorwithout rotation direc tion monitoring The sensor lead is monitored for lead breakage The sensor lead is monitored for short circuits If you check the left box by clicking into it you activate the warning limits Now Lower Limit and Upper Limit turn from grey to black The limit values are entered into the boxes on the right hand side If you check the left box by clicking into it you activate the alarm limits Now Lower Limit Upper Limit and Hysteresis turn from grey to black The limit values are entered into the bo xes on the right hand side Copyright Pepperl Fuchs Printed in Germany Measuring Range Unit Constant Offset Output Malfunction output status 6 3 5 Solenoid Drivers Remote Process Interface Parameter Assignment In the operating mode frequency
239. n nvinsdsteulceviencet eusinsdas aa a 1 12510 ed ENGIN TS GIAO SECS eene E EAEE E EAE E A E E EAER 212 12 3102 SMUAIN CO VICCS sses EEE a eS 212 123103 Process Valit sercas REE E e EE ERE O EaR E E E AE S 213 12 3 10 4 Device specific diagnostic cccecccccssseeecceeeceeceeeeeecsuusceeceeseeeeeceueeeecsaaseeeesaaseeesseaeeeessaugeeesseeeeeessuseeessagseeesseesaeseees 213 123 105 Ghannel specie QIAGMOSUGC ssesssnrcaicesans na E E 213 12 3 11 Other program Options sossccsisisiricsriesrirarrideinenriiineri adine iiaa aaa iieiaeie eaii ken 14 123 11 1 Seting basic program OPTIONS waren inncesttetecctctoiedaesacideassSteandnadscteankunsihal conkenneduesadideansSacatdeaiiohensacenarhdungenseneauatBegiaeenddelaed 214 te TE n A ea E E E E E EE E EE 214 12 3 11 3 Finding out the version of your software ciccscccessindincccddsasesceccbinwes eennttseinnncendsedadeartediacdsnuncenadedbecentenudtiwesneeneccsemearstodenues 215 12 3 12 Exiting the K SK1 software 00 0 ee cecccecceceseeeeceeaceceaceceseaceseaeescesaacececuseeseaneseaneseesecesenseaeessnessanssestsetserssss QO 13 GLOSSARY cece sceece cece ce eccesececteseeuseecne E aa FO Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 11 12 RPI System Manual Table of contents Subject to reasonable mo
240. n of the Device Addresses on the Internal Bus In Section 4 addresses were allocated to the RPI devices while planning the system see Chapter 4 1 8 Layout and Addressing of the RPI Devices Now these addresses must be set in the RPI devices The device addresses are organised as follows Address Device 0 Neutral address of an RPI device the setting on delivery Active RPI gateway Redundant RPI gateway 3 127 RPI device e On selecting the operating mode b ADR INT set internal address using the Mode button on the ga teway the lowest possible free device address is shown on the display e Select the desired device address using the Up and Down buttons Occupied and prohibited addres ses are not displayed e lf the ADR pushbutton on the front panel of the device that is to be addressed is depressed for longer than 3 s e the displayed address is allocated to this device This is indicated by the green LED PWR on the device and the gateway flashing for a brief period Checking the Device Addresses on the Internal Bus On selecting the operating mode C CHK INT there are two principal ways of checking the address of a device 1 By ascertaining the device that has the address that is indicated on the gateway display The address on the gateway display can be set using the YW and buttons Only addresses which are actually available on the internal bus are displayed The green PWR LED flashes on the device whose addre
241. n order as follows e COM driver RPI serial interface HART protocol driver e Gateway or the devices for direct communication with the HART driver e Second gateway for redundant communication with the control system or the first RPI device e RPI devices 3 Open project Select lt File gt lt Open gt Now you can open project PW and start editing it 4 Select COM driver Highlight lt HOST IBM PC gt select the COM driver the RPI serial interface or the HART protocol driver from the menu or from the device catalogue and paste it to the project window In order to project the COM driver you can e click on the COM driver in the right window and drag it keeping the mouse button depressed to HOST IBM_PC in the left window drag and drop or e double click the COM driver in the right window or e click on the COM driver once and confirm the selection by clicking the Paste button down on the right O Note that the level in the left column where you can project the required component should be il activated i e be on a grey or blue background Note This means that if you wish to project a COM driver the HOST IBM PC must be activated for K or E devices the KE GUT driver must be activated and for an RPI device the RPI gateway should be acti vated If this is not the case an error message will appear 5 Select gateway Mark the COM driver select the gateway in the menu or in the device catalogue and paste it to the proje
242. n which closes the window when clicked Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 211 Remote Process Interface K SK1 12 3 10 Diagnosis of devices If an error occurs e g lead breakage limit value exceeded etc the device will be shown in red in the pro ject To get information about the error use Diagnostic all Diagnostics Of course you can use diagnostics also with fully working devices Using the diagnostics is only possible with the PC connected to the RPI hardware an established commu nication connection and a selected device To start the diagnostics select a device in the project manager and do one of the either way press i select Diagnostic all Diagnostics or click the i Diagnostic button The diagnostics window opens jm Pepperl Fuchs K 56 7 DIAG 13 KSD2 Bl Ex4 DIAG 13 FSD2 Bl Ex4 Channel 1 2 Charnel 3 4 EZR ERR I NO APPLERRI NO G WATCHDOG NO Timenut Communication NU Internal Medundancy activel NO LocalAccess NO Parameter Eno NO Diagnostic for 4 channel devices Device _Channel 1 2 Channel 3 4 Channel 1 TAG 1 Short Creu NN lead Areak age 5 NO h r Channel 2 TAG 2 ShortCireut NO LeadBreakage NO
243. ndancy user initiated 84 Check sums of the parameter sets in the active and passive gateway are not the same Tabelle 5 6 Error codes O It is recommended that on the occurrence of an error message the Up and Down buttons il are always pressed in order to be able to detect errors in other devices The RPI system can also be operated without an external bus connected In this case the EXT Note LED flashes It is possible to simulate individual RPI modules during normal operation Bear in mind that simualted signals could interact with your process Further information on maintenance and diagnosis can be found in Chapter 8 RPI in Opera tion Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 79 5 4 3 5 4 3 1 80 Remote Process Interface Configuring and Commissioning the RPI System Operating the Gateways of Type KSD2 GW2 The gateways of type KSD2 GW2 have four buttons OK Esc Up and Down four LEDs and an LC display The function of the LED corresponds to the description in Chapter 5 3 2 onPage 69 The LC display shows the following information e Operating data of an RPI device as well as of the individual channels e Error messages of the RPI devices e Operating modes and paramet
244. ndant operati on When both gateways have been configured the type and method of switching from the active to the redun dant gateway must be established This is achieved by setting the modes for the master of the fieldbus The following modes can be set Value Description 00h Automatic switch over to redundant gateway in the event of the active gateway beco ming defective Like 00 but also in the event of errors in the communication with the host Switch over to the redundant gateway by the host see gateway diagnosis Switch over of the passive gateway into the active mode The active gateway master is setto 01 and the redundant gateway is set to 03 as standard The advantage of this setting is that in the event of an error after which the defective gateway is replaced the gateway which is given the internal address 1 is always active 7 1 6 Exchanging a Gateway The addresses and parameters for the new gateway are set via PC and thePACTware edition 2 human machine interface Normal operation is resumed A status information on the elimination of the fault is trans mitted via the external bus 7 1 7 Exchanging a Gateway External Bus Redundant If the system is redundant due to the use of 2 gateways and two external bus branches one gateway is defined as active priority and the other as redundant If one external bus branch or one gateway fails then communication takes place via the second gateway and the second bus b
245. ned by the following parameters e Type of bus cable used e Transmission rate e External interference effects e Number of bus stations More detailed information on the determination of the maximum lead length can be obtained from EIA 485 or ISO 8482 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Bus termination O On the Modbus each bus segment must be terminated by resistances at both ends of the line Note Bus termination active Rotary switch S1 for bus termination on the Bus termination 0 right side of the device not active Actuating by means S1 of a screw driver Figure 7 3 Rotary switch S1 for bus termination The Modbus gateways operate internally via a switchable bus termination Using a screwdriver the bus ter mination can be activated on the rotary switch S1 on the right side of the housing as viewed from the front This is used if the gateway is installed at the end of a line 7 3 2 Commissioning Before commissioning check once again that all the connections are correct Familiarise yourself with the method of communication between the Modbus master and the gateway Commissioning requires a knowledge of the Modbus and the p
246. ned from Pepperl Fuchs as CD ROM A license number is required to enable the functions Print and Save Licenses with the functionality stated in the table page 138 can be ordered from Pepperl Fuchs Graphic representation of all communication and device DTMs in a tree structure Colour coding to identify affected units and the simulation mode during online ope ration A number of windows can be open at the same time It is therefore possible to view the set device parameters monitor the measurement value and display the device diagnosis simultaneously Generating a configuration by means of a graphical project processing menu Editing of available projects Measuring point descriptions for each channel Offline configuration storing project data on a hard disk drive or a disk Automatic compari son of the project planning to the available system during connection set up on device level and parameter level Wracrses PGE sga BLL h EU oa Pe EE ga AAT Deis PD fo LFO H T Bee E Foordabte bhairt Chiat AA eram E reim Cormar 8 Ii TP m ESU va Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 55 56 PACTware BASIC version Type PW2 BASIC Licenses PW2 P LEVEL PW2 P RIO100 PW2 P RIO500 PW2 ENTERPRISE Parameter assignment of devices Measured value indication
247. nel modules lt SB 1 Byte LS DATA CH1 signed integer WO MSB 3 Byte LSB DATA CH1 signed integer D2 Data type FLOAT 1 channel modules MSB 1 Byte LSB DATA CH1 FLOAT D1 MSB 3 Byte LSB DATA CH1 FLOAT D1 MSB 5 Byte LSB DATA CH1 FLOAT D2 Analogue input data with status Data type signed integer 1 channel modules z SB 1 Byte LSB STATUS CH1 7 Bit D1 lt SB 3 Byte LS DATA CH1 signed integer WO lt SB 5 Byte LS DATA CH1 signed integer WO D2 Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Remote Process Interface Analogue input and output data without status Module types n x 1Al_INT n x 1AQ_INT MSB 2 Byte LSB DATA CH1 signed integer D1 etc Module types n x 1Al_ FLOAT nx 1AQ_FLOAT MSB 2 Byte LSB DATA CH1 FLOAT D1 MSB 4 Byte LSB DATA CH1 FLOAT D1 etc Module types nx 1AlL INT_S MSB 2 Byte LSB DATA CH1 signed integer D1 MSB 4 Byte LSB STATUS CH1 7 Bit D2 etc Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 7 2 9 4 Data type FLOAT 1 channel modules Remote Process Interface Module types n x 1Al_FLOAT_S The position of status bytes and data bytes is the same as th
248. nennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nunn nunen nnmnnn unnan nn nnman nannan nnmnnn OO MSR Technology sa rsctcsocrstantsearonesinseresdteciewiesses diirnaiep oat Ea ESA EER e a O TODOIO seeria a a E r E a a a a a OO HART COmMmMUNICAUON ciccscosccscrcxcecassanalemaacrancieatacsuenersuceuensseeas a e aeaa iii O Fieldbus and Subordinate Service Level nnnnonnnnannannnannannnoennrrnorrnrrnrennrenrrnnrnrrnrernrennrnnrensrnnrensrnrenrere rene OO Establishing the Measuring Ranges Basic and Miscellaneous Functions ccceeceeseeeeeeeeseeseeeesseees GO POCOS S ET E NR E A ee A T E T A E ee ee eee eee 37 Device Parametro sisser averne eiere eiie eiee So terete estes sais Ee eaea eaii 37 Channel Specific Parameters lt tecicreindicaacteaesiuncseusaedleateurdndwecmeseddacwbcauddwpanicbantidesedsadiaddwdaadudwedsetedaiueenntenceddbeineagdenanndl cass 37 Device and Channel Specific Diagnostic Information c cc cecccceecceceeececeeeeecseeceececeeseeceeseuceesaeeeseueeesaeeeseaseesaeeeesanes 37 Overview of Functions and Miscellaneous Functions for Each RPI Device cccccceeececeeeeeceeeeseeeeeseeeeeseeeeesaeeeeeas 38 Selecting the RPI Devices 0 0 cecccececceenseeeceecececeeeeceaneeceusaeeceseseesuanececneseaueaeseeseseessaaeesansseesesesessseessssses OG Establishing the Miscellaneous and Monitoring Functions for the Operation cccsesseeeeseeeeeseeeeseees OG Layout and Addressing of the RPI Devices 0 0 cecece
249. nformation on commissioning the external bus system and the control system will also be found in the technical documentation of your control system and in Chapter 7 Integra tion into the Higher Level Bus System Note Prior to commissioning the bus addresses and if necessary the bus termination must be reset The gateway automatically adjusts to the transfer rate prescribed by the bus master Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Integration into the Higher Level Bus System T Integration into the Higher Level Bus System 7 1 General Notes on Operating the Gateways This chapter provides information on all functions and communications which are identical for all gateways 7 1 1 Gateways of Type KSD2 GW The construction and operation of the KSD2 GW gateways using the controls on the front of the devices is similar for all types They only differ in that they contain either RS232 or RS485 service interfaces O In the case of gateways with RS232 service interfaces the terminal connection and the jack il must not be used simultaneously since simultaneous data transfer is not possible on the inter nal bus Note Gateways with RS485 service
250. ng device data a dialog will prompt asking you whether you il want to save the information in a file or not Confirm with yes if you want to save the information into a file no if not If you close the window without saving to the devicve or a file your informa Note tion is lost afterwards SELECTING THE DEVICE 8 Click onto the device which contains the data you want to change Select Device Data Edit Device Data or click onto Data a Select the device by moving the marker with the cursor keys Press either i or v then e Changing data The available data is device depended Your edit window may look different for each device Also the con tent of the tab strip may vary You are only able to change white or gray text fields on the tab strip To change a field content click into the field Then do your changes Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface K SK1 O After you are finished always safe the changes Ll Note 12 3 6 3 Changing between the tab strips D click on the tab strip you want to edit a use 1 the underlined letter of the register tab strip you want to edit Pepper4 Fuchs K 56 1 4 Building analog valve I1
251. nication oth the RPI internal CAN bus 0 no error 1 local access has taken place on one or more RPI modules via a separate interface e g via a hand held terminal HART protocol transmitted Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Byte 9 RPI System Status MSB LSB sno TOTS 418 2111 RPI configuration error Reserved RPI module error device specific RPI module error channel specific Redundant mode switch request Redundant mode Parameter check fault active passive gateway RPI configuration error 1 the number of RPI modules on the internal bus does not correspond with the gateway configuration O no error RPI module error device specific 1 device specific error in one or more RPI modules 0 no error RPI module error channel specific 1 channel specific error in one or more RPI modules 0 no error Redundant mode switch request 1 in redundant mode with two gateways the gateway expected a mode switch over command 0 no request received Redundant mode 1 RPI in redundant mode O RPI not in redundant mode Parameter check error 1 error when comparing parameter sets of active and passive gateways 0 no error Byte 10 DP Configuration Status MSB LSB amo 7 o siTe user data length error acyclic channel error RPI DP configuration error special ID RPI module overflow special ID RPI DP module
252. nne nn nnmnnn mnn mnnn mnn mnnn n mae Responsibilities of the User s ssasnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nenn nnmnnn nnmnnn nnmnnn nnmnnn nnn menemn nnne nnmnnn enn mnnn SAFETY cenres e E AEE eaten SAN NOIES oeni aE E E EEE EEEa Explanation of the Symbols Used in This Document c ceceseececeeeeceaneeeaeneeecneeeeseaeeeeaneeaeaaeeeeseeeeesans General Safety Regulations cccececessececeaeeeeeeceseececece ana eeceauanseeeeauaceceaeauseeseaueeeeeaeaueeeeeaueaeaeaeaneeeesaneneees Mende USO pecie EE E E EE Installation in a Potentially Explosive Atmosphere cccccescecnseeeeeeeesneeeeeseseeenseaseeeaseaneeseseeanenees Installation Instructions for Use of the RPI System on SHIPS ssssssnssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nenne Overvoltage and Lightning Protection ccccceeeeceeeeeeeeeeeeeeeeesneeeeneeeeeeseeeeaeseeaesaeeaeaseaeanaesoeaeenseeenesanens D claration OF COMM ONIN sassis E e a IVAN OUI marsin E E EEE A ES PRODUCT DESCRIPTION ceacestcasccodavecenecescsaccavecasevecesdececucaceciccesanccecseaedeaccnsaesiccasssacavesiwewewes System Structure and Principle of Operation ccccecesscecescecesceceeececeeeeeesesaeeneeaescensseseaeeeennsnsenenseeas Modularity of the RPI System Integrated Signal Transfer and Mechanical eani Power Rail Gateways Interface to an External Bus Voltage Supply via Power Feed Modules and Power Suyu Un
253. nsfer In the RPI gateway there are two 256 word registers which are accessible to the Modbus Plus master The Read Holding Register starts with register No 1 and the Write Holding Register starts with register No 1025 The data in the Write Holding Register is written by the host via the Preset Multiple Registers function while the data in the Read Holding Register is read via the Read Holding Registers function Both Read Holding Register and Write Holding Register are divided into two sections a Control Register Area first 10 registers and a Data Register Area remaining 246 registers Write Holding Register Write Holding Register Read Holding Register Read Holding Register Holding Register Area Register area 1025 1026 Control Register Control Register Area Area 11 12 Data Register Data Register Area Area Figure 7 6 Read Write Holding Register comet Generally the Control Register Area is used for the Modbus Plus master device to send commands and read responses to or from the RPI gateway Structure of Control Register Areas Write Holding Register registers 1025 1034 Of the ten registers available only the first register No 1025 is used to transfer commands The remaining regisers are not used and contain 0 Register Description of Write Holding Register 1025 HOST command register used for commands to be sent to the Modbus Plus gateway 1026 1034 not used and should be cleared
254. nt literature oe The PROFIBUS user association PROFIBUS Nutzerorganisation e V PNO Karlsruhe pub lishes information brochures and a PROFIBUS product catalogue PROFIBUS Nutzerorganisation e V Haid und Neu Str 7 D 76131 Karlsruhe Tel 0721 9658 590 http www profibus com Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 115 7 2 4 7 2 5 7 2 5 1 7 2 5 2 7 2 5 3 7 2 6 116 Remote Process Interface Features of the PROFIBUS Gateways The KSD2 GW PRO KSD2 GW PRO 485 and KSD2 GW2 PRO RPI gateways connect the internal RPI bus to the external PROFIBUS The gateway thus assumes the master function for the internal bus The ga teway has the function of a modular DP slave device on the external PROFIBUS To increase system avai lability the gateway and external bus can be implemented in a redundant configuration Device Connection The electrical connection of the PROFIBUS DP gateways by means of cables merely involves establishing the PROFIBUS connection Gateways of Type KSD2 GW PRO and KSD2 GW PRO 485 The RS 232 interface is only used to configure the RPI system To do this the PC with the PACTware human machine interface is connected to the jack on the front of the gateway via the K ADP2 adapter If the PC is to rem
255. nted in Germany 84 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Configuring and Commissioning the RPI System Esc OK Monitor Run Esc Up Down Up Down Up Down OK Assign E t j t Up Down Up Down Up Down Red Mode ReselntCom ReblidSingleLp Up Down Up Down Up Down ne SetActiveMode RebAllLps Up Down Up Down Up Down vee Info PerfMode Up Down Up Down Hst Adr LongFrAddr Figure 5 10 Service menu 5 4 3 8 General Information on Input of Parameters and Values The input mode is selected by depressing the OK button for every menu item of the Service menu The display flashes and can be changed using the Up and Down buttons within the predefined range of va lues Esc guides the user back to the source value OK confirms the indicated value which stops flashing Esc guides the user back to the service menu Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 85 Remote Process Interface Configuring and Commissioning the RPI System The following diagram shows the input of parameters and values This procedure applies to all variable pa
256. o menu items Some of the buttons may not always be available You can use them instead of the menu bar Note that not all functions have a short cut The title bar The title bar of this window states the name of the present project Selecting an item a Click onto the item with the left mouse button E Use the cursor keys to move up or down to the item The up and the left key move to the item above the down and the right key to the item below The structure level buttons The four structure level buttons below the title bar control the level of the presented structure Level 1 is the serial port level level 2 the gateway level level 3 the RPI devices level and level 4 the channel level If you need to see the full information of the device tree make sure that level 4 is selected The use of those buttons is simple 8 Click onto the structure level button with the left mouse button The whole tree is expanded or shrunk to that level If you want to expand or shrink only parts of the tree you have to double click onto the item with the branch to change If nothing happens your selected item does not have a minor structur a Use the cursor keys to navigate in the tree Up and left select the item above down and right select the item below Use enter to expand or shrink a branch Peppers Fuchs K 56 1 Edit Project Peppers Fuchs KSK 1 7 Edit Project Ey Project dit Clipboard Qiptions fenm Help oject fren Pmi o SS
257. o provide the bus cable between the gateways and the control system lf there are a number of RPI systems the bus line runs from gateway to gateway i e only one separate cable has to be laid to the control system Only in the case of a redundant design with two ga teways per RPI system are two mutually isolated bus systems required to the control system e Providing the voltage supply cables for the power feed modules or power supply units AN When using 90 240 V power supply units the power cables and the signal or bus lines should not be laid in the same cable duct Attention e Possibly another cable string for the service level must be laid This is the fixied wiring between the ser vice interface of the gateways and the Engineering PC It can be used for HART communication for a separate diagnosis of the RPI system or for a software engineering tool e The HART protocol transmission via the HART multiplexer possibly requires an additional cable Due to the fact that only a few cables are needed in the non Ex area the space required in the control ca binet will be considerably reduced 4 11 4 Installing the Devices Snap the power supply modules gateways and RPI devices onto the mounting rail Power Rail assembly Arrange the devices to suit the field cables The order of assembly on the Power Rail is not a significant factor from the standpoint of the internal bus system When snapping the devices on the rail they should not b
258. ocess Interface Planning of the RPI System 4 8 1 2 Mounting the UPR 05 Power Rail You should proceed as follows e Cut the mounting rail including the Power Rail insert to arbitrary length using a hack saw e Remove the Power Rail insert by means of the end caps e Screw or rivet the mounting rail onto a mounting base M4 screws and DIN 125 washers or 4 mm rivets are required for this purpose e Snap the Power Rail insert into the mounting rail e Replace the end caps e Inthe case of vertical mounting of the mounting rail TS 35 Type 12 end clamps should be screwed to the rail at the required intervals in order to provide mechanical protection of the RPI devices e Having mounted all RPI devices the cover is cut according to the gaps between the modules The cover must be snapped in place in order to provide protection against accidental contact IP 20 4 8 1 3 Accessories for Power Rail UPR 05 The following accessories are available e UPR end caps see Figure Figure 4 7 e TS35 type 12 end clamps see Figure Figure 4 8 providing mechanical protection of the RPI modules when they are installed on a vertically fixed mounting rail At least one clamp per vertical mounting rail is required for this purpose 2 leads for power supply 1 lead HART signals fui 2 leads for bus connection universal Power Rail Mount using M4 screws with washers per DIN 125 DIN Rail 35 mm x 15 mm Slot mounted Power Rail Figure 4 7
259. of issue 05 27 03 Remote Process Interface Structure of diagnostic byte 1st module diagnostic byte MSB LSB sno ee eee 1 module with address 0 with a diagnosis 1 module with address 1 with a diagnosis 1 module with address 2 with a diagnosis 1 module with address 3 with a diagnosis 1 module with address 4 with a diagnosis 1 module with address 5 with a diagnosis 1 module with address 6 with a diagnosis 1 module with address 7 with a diagnosis The following 7 module diagnostic bytes contain the appropriate information for all further modules defined in the configuration max 64 Channel specific diagnostic information The channel specific diagnostic data follows the module specific diagnostic data in order for all modules that have been diagnosed The length of each diagnostic entry is 3 bytes Byte 1 Module number MSB LSB anoj 7jejsjajaj2jijo l Type number 0 63 Fixed on 10 Byte 2 Channel number MSB LSB ome 7 e eTe Channel number 0 63 In output channel OO Reserved 01 Input 10 Output 11 In Output Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 131 132 Byte 3 Type of diagnosis MSB LSB so 7 GES ESE Remote Process Interface Error type Channel type 000 Res
260. ons due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 215 13 216 Glossary Ox ADR CAN bus CH CHK COM COM DCOM DDLM DC DP E A EEPROM EMC ERR Ex side EXT FDL FMS GND DTM FDT HART I O INT LCD LED LSAP LSB MSB MSR Subject to reasonable modifications due to technical advances Remote Process Interface Glossary Hexadecimal representation Address RPI internal data bus Channel Check Communication Communication Object Model Distributed Communication Object Model Direct Data Link Mapper Direct Current Distributed Peripherals Eingang Ausgang I O Input Output Electrical Erasable and Programmable ROM Electromagnetic Compatibility Error Side of a device from which circuits lead to environments in which explosive atmosphe res can arise External Fieldbus Data Link Fieldbus Message Specification Ground Device Type Manager Field Device Tools Hexadecimal representation Highway Adressable Remote Transducer Input Output Identification Internal Liquid Crystal Display Light Emitting Diode Link Service Access Point Least Significant Bit Most Significant Bit Mess Steuer und Regeltechnik Measuring and Control Technology Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel
261. ood value __ Nolimitvalue reached lLowerlimitviolted 10o Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 149 Po Te e a a of tf of oft of o0 Pe eet o of f F lo EE oe of D F lo 150 Remote Process Interface Reading analogue input data 1 channel devices All the measured values from single channelled devices are represented in this area as a function of the current RPI address The register addresses can be obtained from the following equations Data format Register address Signed integer 2 RPI address 3 4742 Floating point 3 RPI address 3 6409 Two registers have to be read in the signed integer format The data is constructed as follows Register address 1 Register address Status Channel 1 In the floating point format 3 registers have to be read These are constructed as follows Register address 1 register address Data byte 2 Data byte 1 Not used Status Register address 2 Data byte 4 Data byte 3 Reading analogue input data 2 channel devices All the measured values from 1 or 2 channelled devices are represented in this area as a function of the current RPI address The register addresses can be obtained from the following equations Data format Register addr
262. or PROFIBUS DP Chapter 5 Configuring and Commissioning the RPI System provides an explanation of the RPI system configuration by means of the gateway pushbuttons and of the menu struc ture Construction of the devices LED red Communication LED red Internal communication LED green Power supply LED yellow red External bus AS 232 3 5 mm Jack bush RS 485 Serviceinterface Figure 7 2 Front view of the KSD2 GW2 gateways Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com LC Display Button ESC Button Up Button OK Button Down Rotary switch termination resistor _ for PROFIBUS Removable terminals green Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Integration into the Higher Level Bus System Data Formats Analogue values of the different RPI modules or values for the configuration and parameterization of the system can be transmitted either in signed integer integer numbers or in floating point format Floating point arithmetic In the case of both RPI internal communication and communication to the host computer the floating point values are transmitted with single precision in accordance with IEEE 754 short real number The values are stored
263. or case is determined according to the application Malfunction output status Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Parameter Assignment Current Frequency Converter Batch Controller The Parameter tab contains both device specific and channel specific parameters Figure 6 10 Parameterizing KSD2 F Device Address Tag Data Tag Name Sensor Unit Operating Mode Lead breakage detection Short circuit detection Limit Values Warning limits active Alarm limits active Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 101 lt 008 gt KSD2 Fl EX Parameter J Ioj xj Device address i Address fe T a Device address Channel Channel 2 Address js Tag data i 5 Tag name PO Channel 1 Channel 2 Sensor Channel 1 is only used to reset the counter on channel 2 Therefore the channel has no Einheit Hz parameters e Operation mode Frequency input without direction detection I Lead breakage detection M Short circuit detectio
264. oring appli cations However the RPI system will be continuously extended in order to satisfy customer requirements The RPI system can be combined with Pepperl Fuchs K system devices thus covering a large number of special applications Further information can be obtained directly from Pepperl Fuchs 3 3 1 230 V AC Power Supply Units e KFA6 STR 1 24 4 4 A Power Supply Unit 3 3 2 24 V DC Power Feed Modules e KFD2 EB RPI 4 A Power Feed Module with bus pick off e KFD2 EB R2A RPI 2A Power Feed Module with bus pick off for redundant voltage supply from two power supplies 3 3 3 Isolated Switch Amplifiers e KSD2 BI Ex2 2 channel Isolated Switch Amplifier with Ex approval e KSD2 BI Ex4 4 channel Isolated Switch Amplifier with Ex approval e KSD2 BI 4 4 channel Isolated Switch Amplifier for the connection of passive contacts e KSD2 BI 4 2 4 channel Isolated Switch Amplifier for the connection of proximity switches and mechanical contacts 3 3 4 Solenoid Drivers and Relay Modules e KSD2 BO Ex 1 channel Solenoid Driver with Ex approval e KSD2 BO Ex2 2 2 channel Solenoid Driver with Ex approval e KSD2 RO Ex2 2 channel Relay Module with Ex approval e KSD2 RO 2 2 channel Relay Module 3 3 5 Transmitter Power Supplies e KSD2 CI S Ex 1 channel SMART Transmitter Power Supply with Ex approval e KSD2 Cl S 1 channel SMART Transmitter Power Supply e KSD2 Cl 2 2 channel Transmitter Power Supply e KSD2 CI Ex2 2 channel Transmitter Power Supply with Ex approval e KSD2 Cl S
265. ote This means that in a project consisting of a COM driver and devices the changed settings must be down loaded twice for the COM driver and for the device separately Il In addition the overall project should be stored on data carriers by using Save project Note Properties Tab The individual DTMs offer information on themselves and on the devices to be edited using these DTMs The Properties tab contains the Device Info and Description tabs Device Info Device Info provides unchangeable information on the selected device The following information can be obtained from the card e the data source e the time when the module specific data was generated e the time when the last change was made e the device type e and the description of the device Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 93 6 2 94 Remote Process Interface Parameter Assignment Additional information is read out of the device as soon as a first connenction to the RPI system is set up e Serial number e Software version e Hardware version Description Using Description you can store data which is specific to a measuring point e g tag data and tag name il This information is only stored in t
266. ou to save this informa tion on your PC This storage is of great use as a system backup for the case you have to exchange com ponents later K SK1 Operation manual This part guides you through the configuration process of a RPI system It shows you how to use the project manager and the tools provided Starting the software Double click the K SK icon Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 12 3 2 Structure level button Remote Process Interface K SK1 Select the language and operation mode in the dialog box comming up Use specialist if you need to set up a new project or edit an existing one otherwise select maintenance If you select specialist mode you might be asked for a password when you try to establish a connection to the gateway If you do not possess the password exit the program and start in maintenance mode Confirm your choice with OK Select Language and Level Language Operator C Maintainance Specialist Lancel The main screen After fully loading the program the screen displays this window Title bar Menue bar Short cut buttons E Pepperl Fuchs K SK 1 7 LEER PRJ Project Connection Display Diagnostic Oevice Data Ont sas Ext Help F2
267. our application it can be also be a reduced by dividing the RPI devices between 2 or more gateways ote Planning the Internal and External Communication General Notes on Operating the Gateways RPI gateways of type KSD2 GW and KSD2 GW2 translate the protocols of the internal bus into the protocols of the external bus to the control system and vice versa Up to 125 RPI devices with a maximum of 500 channels can be connected to one gateway O The actual number of devices which substantially depends on the transmitted data protocol il should be determined taking account of the bus specific conditions Detailed information is given in Chapter 7 Integration into the Higher Level Bus System Note The construction and the operation of the gateways using the controls on the front of the devices is identical for all types Differences are referred to in the respective descriptions Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Construction of the devices Front View Housing type B2 see system description LED red Internal communication LED yellow red External bus Mode button RS 232 3 5 mm Jack bush KSD2 GW PRO Front View LED red Co
268. overflow special ID DP module ID different to RPl module ID special ID module data length error special ID module number error Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 e Internet http Avww pepperl fuchs com 129 130 User data length error Acyclic channel error RPI DP configuration error Special ID RPI module overflow Special ID RPI DP module overflow Special ID DP module ID different to RPI module ID Special ID module data length error Special ID module number error Byte 11 Status counter Remote Process Interface 1 max process data length of 244 bytes exceeded 0 no error 1 acyclic transmission error module 0 access 0 no error 1 the RPI configuration does not correspond with the configuration of the DP master 0 no error 1 more than 64 RPI devices have been configured 0 no error 1 more RPI devices have been configured than there are DP modules available 0 no error 1 the device ID in the identifier of a DP slave module does not correspond with the device ID of the assigned RPI device 0 no error 1 the defined user data length of the RPI and DP configurations do not correspond 0 no error 1 the number of RPI devices to be packed does not correspond with the special identifier 0 no error
269. p Awww pepperl fuchs com 83 Remote Process Interface Configuring and Commissioning the RPI System 5 4 3 6 Error Messages The following error messages are indicated and abbreviated Data structure Comment CdS O Devis Device rotavalabe Eno Devnotconf Devicenot configured OoOo o O e ig Dev Wono O per Devem Device causesemor_ rs hn err Channel causes enor per Lin err_ Errorininearizationtable ror Aci Conf Two devices with same address O S nwe sm Device in simulation mode O APPLERR nT _ mtemainterface PCAN FAULT CNH CAN Bus connection short circuit PCAN FAULT CANL CAN Bus connection lead breakage Co T Aomer NOT DEF Notdefined or supported Func Diag short eRe SC Co T esee B oS ionm lowr lowsignal waming Coo T mam wR High signal warning LOL ALM Loam bowsignai alarm LLM MAM High signal alarm P SUNDER RANGE OUR Pp y T oee OORT SSS O Aloe NOT DEF Notdefinedorsuppored 5 4 3 7 Input of Configuration Data Service Menu The data for the configuration of the gateway HART transmission and the address allocation to the RPI devices can be entered in the Service menu User prompting via LC display is shown in the diagram below The service menu is entered by simultaneously depressing the Esc and OK buttons and reconfirming with OK Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Pri
270. p Warming The simulation changes 1 0 values independent from the process If you have the system connection to a loop control you should be sure that the automation is set to manual F Do not show this warming again i CE Cancel Figure 8 4 Warning prior to starting a simulation AN If you are not authorized or do not wish to intervene in the process select Cancel to close the window and exit the Simulation menu Attention Confirm the warning with OK to proceed If you proceed you are asked to choose the features you want to simulate There are three simulation options available Process Value Device Specific Diagnostic and Channel Specific Diagnostic Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 176 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface RPI in Operation 007 gt KSD2 TI EX Simulation gt IO x j lt 007 gt KSD2 TI EX Simulation S x Device System OT Internal Memuy Emo OF intemal Memory Eirg Atal OT Intemal Interlace Ernu O Intemal interface Era c Sa CYT Ener in parametrization FF Error in parametrization I l T Activate simulation Device System o Device System Derce System EE E Process value Fig
271. paths to the control system thus avoiding the danger of both cables suffering damage simultaneously Determining the Number of RPI Gateways Required Obtain the number of gateways required by consideration of bus specific conditions see Chapter 7 Inte gration into the Higher Level Bus System One gateway can manage up to 125 RPI modules It should also be noted that twice the number of gateways are required if the gateway or the external bus system is required to be redundant Establishing the Service Functionality for the RPI System Service Interface RS232 If the PC is only used for commissioning or adjusting the RPI system the RS232 service interface with a jack is selected Using the adapter which is available as accessory the RPI system can be configured and parameterized A PC can also be connected directly to the terminals of an individual gateway Service Interface RS485 Up to 31 gateways can be networked and connected to a PC via the RS485 service interface This allows a wired service level to be arranged e g for continuously monitoring the RPI systems O il Gateway KSD2 GW2 PRO has both types of interfaces Note PROFIBUS PROFIBUS DP The RPI system can be parameterized via PROFIBUS DP using the GSD file PF0818p GSD More infor mation is provided in Chapter 7 2 8 GSD Files PROFIBUS DP V1 The application of PROFIBUS DP V1 will enable users to perform a parameter assignment PACT produc or HART dir
272. perl Fuchs Printed in Germany 86 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Configuring and Commissioning the RPI System The device addresses are organised as follows Address Device 0 Neutral address of an RPI device the setting on delivery Active RPI gateway see Set Gateway Mode Redundant RPI gateway see Set Gateway Mode 3 127 RPI device 5 4 3 11 Activation of the Redundancy RedMode Service Menu The redundancy function of the gateway is determined in this menu The priority gateway obtains the setting master Mst and hence also the internal address 1 the redundant gateway is set to Red and thus ob tains the internal address 2 5 4 3 12 Setting the Address of the RS 232 RS 485 Service Interface ParAdr Service Menu PACT ware human machine interface supports the simultaneous connection of a PC to a number of gate ways as a subordinate service level Up to 31 gateways can be managed and wired with the RS 485 inter face of a PC Each individual gateway can be connected to a PC by means of an adapter cable via the RS232 interface in the gateway Parallel operation of the two interfaces is possible Establishing an address from 0 to 255 for the parameterization interface is possible by means of the Parm Address menu 5 4 3
273. perl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 49 4 7 8 4 8 4 8 1 4 8 1 1 50 Remote Process Interface Planning of the RPI System The decoupled diodes required must be either e in the power supply units that are used e sited externally in the power supply circuit e orin the KFD2 EB R2A RPI power supply module two units of which are mounted on each Power Rail segment The KFD2 EB2 RPI power feed module is used e when the supply has no redundancy e when the supply has a redundancy and external decoupling diodes are used The current for a Power Rail is a maximum of 4 A Note Establishing the Type and Number of Power Supply Units where Required The RPI operates with a voltage supply in the 20 to 30 V DC range and requires no additional power supply units If however it is required to operate with a voltage outside this range the KFA6 STR 1 24 4 power supply unit will have to be used input 90 to 265 V AC output 24 V DC If a 24 V DC power supply is available in the control cabinet or within reach power supply modules should be used In this case you should proceed as follows e set up the power supply balance for your RPI system e determine the number of power feed modules that are required as shown in Chapter 4 7 5 If no 24 V DC supply is available the KFA6 STR 1 24 4 power supply unit should be used O When usin
274. possible to detect errors in the RPI system from the control system engineering console If all diagnostic functions are implemented access to the complete data for the connected gateways and RPI devices will be available as when detecting errors using the RPI human machine interface Measured values status values configuration data and parame ters Fault elimination within the RPI System The fault diagnosis shows whether the error lies in the field circuit in the internal or external bus system in the parameterization or in the device itself If the fault lies in the device then it can be replaced by a new one Replacement in the case of failure of an individual device The device is replaced by another of similar type which is set to the neutral address 0 Communication with the gateway commences immediately The gateway overwrites the address 0 with that of the replacement module The parameter set is transferred to the device following storage in the gateway Normal operation is resumed A status message regarding the elimination of the fault is transmitted via the external bus O The failure of one or more devices has no effect on the function of the remaining serviceable il devices Note Devices intended for replacement purposes should be set to the neutral address 0 Otherwise on the replacement of an individual device the automatic address assignment cannot take place In the event that the new device has an address other than
275. pter 4 1 1 Topology see chapter 4 1 2 number and type of the devices see chapter 4 1 5 4 1 6 Number of gateways see chapter 4 5 3 Determination of the total power see chapter 4 7 5 Number of power feed modules or power supply units see chapter 4 7 7 Number of Power Rail segments see chapter 4 9 Space requirement Number of switch cabinets see chapter 4 9 4 10 Figure 4 1 Planning procedure Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com HART or SMART communication see chapter 4 1 3 Fieldbus system see chapter 4 1 4 Gateway redundancy see chapter 4 5 2 Type of gateway Type of voltage supply power feed modules or power supply units see chapter 4 7 Copyright Pepperl Fuchs Printed in Germany 35 36 Remote Process Interface Planning of the RPI System MSR Technology First of all you should determine the type and number of measuring points field devices actuators and con trol circuits required for the application They are intended to communicate with the higher level process control system or with the PLC via the RPI system The individual sensors and actuators are connected to the RPI devices using conventional wiring The kind of information on system side devices required for a parameter assi
276. pyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface The Remote Process Interface RPI in Brief When installing commissioning operating and maintaining RPI and MSR technology devices and device components in hazardous areas the applicable construction and installation regula tions DIN EN 50020 DIN VDE 0165 must be observed Attention Please consider all locally applicable regulations and directives when planning and configuring plants and systems abroad Especially in North America other regulations and directives apply than in the CENELEC member states As planner installer and operator you are responsible for complying with all regulations and di rectives for potentially explosive environments 1 5 Responsibilities of the User Personnel undertaking commissioning should be familiar with the devices and both read and understand the handbook prior to installing and commissioning the Remote Process Interface Various procedures and instructions in this handbook require special precautions in order to guarantee the safety of the persons involved The devices may only be operated and maintained by persons who are authorized due to their special training and qualifications and who have read and understood this handbook In addition t
277. r ce ne ee eee ee ea en ee ae eee CONS TONIN eo eccietecter scapes conte nite E E EE E E E E SE T N Data Transfer on the Modbus PIUS 2 0 cece ce cece scence eee ee eee cess ees eeae ease eecseeaeeeseeeegeeggeeaueageeaneaeeeanseseeenes Structure of Control Register Areas ccccccccecececeetececeaeeneceaeaeeneceaesaceeeeaesaeseaeaneeeesanseeeeassneseesaneeeseesaeeess Gateways for ControlNet KSD2 GW CN and KSD2 GW CN 485 Caaan DOV ICS CONN COMA METNE ContolNet AGG CS Sores ccrscndcrsaytoternee doacsceed secede een scunc a eiea a eranen aiian iiaeiai Macatee keds COMMISSIONING sssr e a Aaa Operation on the ControlNet 20 ccc cecccceeseeceaeecece ee eceaeeseeceaeeeeaeeeeeeaeeeeaeeaeeseaeseeeeaeeeeaeeeeaeaeeseeseseeeeaeeeeaeas DECEASE a ceabansalotecasionshasecemasgasucatadosanietesuawadsen or ansudanas nasiaeonnachadrannacedabeeaectanGesaverandeeinneaiaterararansenatons COMMANA RESPONSE Transmission 0cccceeccceececeeceseesceseeeeceeneceeececueceaaeecaeecesaeaeeneeaegeesseseeaeessaneseaeeees Subject to reasonable modifications due to technical advances RPI System Manual Table of contents Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com Date of issue 06 03 03 Date of issue 06 03 03 8 1 8 2 8 3 8 3 1 8 3 2 8 4 8 4 1 8 4 2 8 4 3 8 4 4 8 5 8 5 1 8 5 1 1 8 5 1 2 8 5 1 3
278. r the parameter assignment the PC is connected to the gateway on the service interface RS232 by means of the K ADP2 adapter or RS485 by means of the K ADP4 adapter After that the project which was generated offline is downloaded to the gateway see Chapter 6 4 Downloading Project Data into the Gateway When installing a service level with fixed wiring adapters are not necessary since the networked ga teways can be controlled directly from the PC via RS485 Having transferred the configuration and parameter assignment data the LEDs and the gateway display indicate possible faults A verification of the RPI system can be carried out using the diagnostic and simu lation functions provided by the PACT are man machine interface The individual fault signals of the RPI mo dules and the fault signals of the gateway are described in Chapter 5 Chapter 6 and Appendix A O Commissioning of the gateway on the higher level fieldbus is described in Chapter 7 Note O During the configuration and parameter assignment of the RPI system the red LEDs light up to il indicate possible faults While proceeding with commissioning the LEDs extinguish and at the end of the commissioning procedure the only LED still illuminated is the bus external LED Mets since an integration into the higher level bus system has not yet been carried out Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Peppe
279. ranch A status information on the interference is transmitted via the external bus branch The addresses and parameters for a new gateway are set by means of a PC and the PACT are edition 2 human machine interface Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 113 7 2 7 2 1 114 Remote Process Interface Gateways for PROFIBUS DP Gateways KSD2 GW PRO and KSD2 GW PRO 485 Gateways of type KSD2 GW PRO and KSD2 GW PRO 485 support the cyclic PROFIBUS DP data protocol in accordance with EN 501 70 8 2 The KSD2 GW PRO gateway has an RS232 service interface both in the form of a jack on the front and on screw terminals The KSD2 GW PRO 485 gateway has an RS 485 service interface which is merely connected to the screw terminals The controls consist of an LC display with 3 1 2 digits and the three buttons Mode Up and Down Dh aia LED red E cole m Communication Jaai i h F al LED green Power supply LED red Internal communication LC Display LED yellow red External bus Button Up Button Down Mode button Rotary switch RS 232 i termination resistor 3 5 mm Jack bush ly e for PROFIBUS Removable terminals green Figure 7 3 KSD2 GW PRO gateway
280. ransmit the commands for the I O data structure the redundant mode or the diagnosis and the gateway responses 7 5 6 Data Transmission The RPI ControlNet gateway can transmit up to 450 data bytes which consist of 225 input and 225 output bytes The data in the Input Area is transmitted from the RPI gateway to the host and the data in the Output Area is transmitted to the gateway Both Input and Output Area each containing 225 bytes are divided into two sections a Control Area 10 bytes and a Data Area 215 bytes Ld Output Area Input Area Output Control Input Control Area Area Word 10 Output Data Input Data Area Area Word 224 Figure 7 8 Output Input Areas configuration Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 171 172 Remote Process Interface Structure of the Output Control Area Of the ten areas available only the word 0 is used for the command counter Word in Output oo l l Control Area E Description of the Write Holding Register 0 High 0 Low Command Counter Detects commands which are transmitted by the host to the gateway via O the unscheduled service vao esea Structure of the Output Data Area The data structure of the Output Area depends on the configuration of the RPI modules It may
281. re Device Type Managers DTM are available for each RPI device As far as compatibility with other configuration tools is concerned your local Pepperl Fuchs sales office will be pleased to advise you O In this section the RPI specific features of PACTare are discussed A detailed description of il the human machine interface PACTware edition 2 can be obtained from the Handbook Note PACT ware edition 2 The handbook can be downloaded free of charge from http www pep perl fuchs com pa accessories pactware main html The PACT zre Parameterization Window In general on the PACT are human machine interface the screen is divided into two windows The left window shows the project tree while the right window shows the respective edit windows The DTM settings for each RPI device see section 6 2 are carried out in a parameterization window Parameter Tab You can access all settable parameter values of the selected RPI devices via the Parameter tab Informa tion that cannot be changed is displayed in light grey The data of this tab can be 1 saved into a file 2 saved to the device On clicking the Save to device button PACTware edition 2 after requesting sets up a connection to the selected device and loads the data to this device O Using Save to file or Save to device the data of the activated device or the COM driver is stored Il whereas the remaining data of the project is not stored N
282. re and regulations Further information on overvoltage filters and lightning protection barriers to be snapped onto the top hat rail can be obtained from the Pepperl Fuchs DIN Rail Housing catalogue 2 6 Declaration of Conformity Pepperl Fuchs offers various devices and gateways for the modular Remote Process Interface RPI The different types of devices and gateways can be found in Chapter Product description or in the Pep perl Fuchs catalogue The TUV 00 ATEX 1617X statement of conformity contains all device types of the RPI system without relay output for installation in Ex zone 2 hazardous areas KSD2 BI 4 KSD2 GW PRO soca J o oo oo CA socom J o Kso2cosee Kso2cosexH J o sone To Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 21 2 7 22 Remote Process Interface Safety The T V 00 ATEX 1618X statement of conformity refers to all device types of the RPI system with relay output as well as power feed modules for installation in Ex zone 2 hazardous areas KFD2 EB2 KSD2 EB RPI KFD2 EB2 B KSD2 EB R2A RPI KFD2 EB D1A B KSD2 RO Ex2 O The current T V OOATEX 1617X and T V 00 ATEX 1618X declarations of conformity can be il obtained from Pepperl Fuchs GmbH or downloaded as pdf file from our website w
283. reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 9 4 3 2 Subject to reasonable modifications due to technical advances Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com Remote Process Interface Configuring and Commissioning the RPI System Esc OK OK Service Bin Monitor see chapter 5 4 3 7 Esc Esc see chapter 5 4 3 4 if an error occurs if no error occurs A008 A pi Down Opstate A012 A Err 2 Up Down ri Down ScanState A054 A Err 5 Up Down Up Down NumOfinst other error messages Figure 5 8 Standard menu HART Communication HART Menu Depressing OK guides the user from the Run normal mode to the display mode Here the user can toggle between the display of the process data and the display of the HART communication status HART communication status e OpState HART communication active e ScanState HART communication in scan mode e NumOfinst Number of installed HART loops O il In order to carry out HART communication the HART support of the gateway must be activa ted See Chapter 5 4 3 7 Input of Configuration Data Service Menu Note Copyright Pepperl F
284. requisite for this is that the RPI addresses of the devices are consecutive Further information on the relationship between RPI address and data range can be obtained from the relevant to pics within this section Register addresses for channel based registers Reading a channel This data is deposited in register table 2 which can be called up via the function code 02 The register address depends on the RPI internal address of the device and on the channel It can be de rived from the following equations max Channel No Register address 8 RPI address channel number 1 8 4 4 RPI address 3 channel number 1035 RPI address 3 127 channel number 1 4 The information is represented as follows Of of oto olTolt ofofL_of ot oto of o 0 ch Reading a number of channels and or status information This data is deposited in register table 4 which can be called up via the function code 04 Analogue input data is usually read from the input registers register table 04 of a Modbus station by PLCs or process control systems In exceptional cases it may be that control of the access to the input register is not supported In these cases the correct register address can be obtained from Chapter 7 3 13 RPI devices with a maximum of 8 channels without status 1 device per register All data from 1 2 4 and 8 channel devices is filed in this area The register address is obtained from the following equatio
285. ress 4225 Bit O E 2PROM error Local access e g HART communication Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 160 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface The gateway diagnostic information is deposited bitwise in register addresses 8 to 23 in Table 2 or wordwise in register addresses 8 528 1538 2064 3080 and 4225 The individual bits have the following meaning Table 2 Register addresses 8 528 Meanin Register adr 1538 2064 3080 and 4225 g 8 Bit No 0 E2PROM Fehler 9 Bit No 1 Internal interface error 10 Bit No 2 Watchdog 1 Bit No 3 TIN Time Out 2 Bit No 4 Communication mode switch over from differential to common mode Local access e g HART protocol ee Reserved RPI configuration error 1 or more devices too many RPI configuration error 1 or more devices missing RPI configuration error 1 or more incorrect device ID s RPI configuration error device specific 0 RPI configuration error channel specific 1 1 switch over of the redundant gateway to active mode if automatic switch over has not been selected 2 Redundant mode 0 passive 1 active Binos Reserved Error codes are given in Appendix A which are indicated in mode A on the gateway display
286. ress 3 6409 Analogue outputs 2 channel device 3 RPI address 3 5641 5 RPI address 3 7567 Analogue outputs 3 channel device 6 RPI address 3 2072 8 RPI address 3 536 Reg Tab Signed integer format Floating point format SS E Special case holding register binary input or output data Binary inputs with status max 4 channels 2 RPI address 3 2751 Binary outputs with status max 4 channels 2 RPI address 3 2501 Special case holding register analogue input or output data and status information Floating point Analogue inputs 1 channel device 2 RPI address 3 1376 Analogue inputs 2 channel device _ 2 RPI address 3 1626 2 RPI address 3 376 4 RPI address 3 626 Status information RPladdess 1126 Other available register addresses Reg Tab Register address Device ID RPI address 4096 Ss Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 16 25 7 4 7 4 1 7 4 2 164 Remote Process Interface Gateways for the MODBUS Plus Gateways KSD2 GW MPL and KSD2 GW MPL 485 The KSD2 GW MPL and KSD2 GW MPL 485 gateways supports the command and response telegram in accordance with MODICON Modbusprotokoll Reference Guide PI MBUS 300 Rev D The KSD2 GW MPL gateway is provided with an RS232 service inter
287. rl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 95 Remote Process Interface Parameter Assignment F PACT ware Device catalogue ie Fie Edit View Device Esras Windows Help lejxi l8 xi 2 amp HOST PC PACT ware EF g lt COMT gt RAFI Serial Intetsce E PEPPERL FUCHS GmbH ns sito 001 gt KSD02 G V PRO 485 f Samson AG E PEPPERL FUICHS GmbH HAR Gae 003p KS02CISEKH PACT ware Clipboard P Barcon M V1 4 PEPPERL FUCHS GmbH Pressure a px a peril Batconintem PEPPERL FUCHS GmbH HART ia ai ane Keno awPAD i iw com KE 300 PEPPERL FUCHS GmbH K E Devices ip 00 KSD2CISEXH By CAG Driver PEPPERL FUICHS GmbH CAG E aa lt 004 gt KSDZBI EXA GBED2UT PEPPERL FUCHS GmbH K E Devices E ar 005 KSD200 5 EXH Ti Genenc Haat PEPPERL FUCHS GmbH HART es 006p KSD2 B0 EX2 2 HART Dover FOT PEPPEAL FUCHS GmbH HART Eha c00 KSD2 TI EX IS API Analoges Eingangsm PEPPERL FUCHS GmbH ISRPI GHW com KE 300 lt COM1 gt KFDO HMS 16 PEPPERL FUCHS GmbH HART Muliplexer F KFD2GU EX BP KFD2 CAG EX1 D PEPPERL FUCHS GmbH CAG FP KFD 2 GU PEPPERL FUICHS GmbH K E Devices KFO2 GU EX1 FEPPERL FUCHS GmbH K E Devices KFD2 HMM 16 PEPPERL FUCHS GmbH HART Multiplewer SP KFD2 UT PEPPERL FUCHS GmbH K E Devices aby KSD2 B1 4 PEPPERL FUICHS GmbH RFI da KSD2 B1 4 2 PEPPERL FUCHS GmbH API aby KSD2 B1 EX2 PEPPERL F
288. rl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Configuring and Commissioning the RPI System 5 2 Power Supply The power feed modules are connected to a 24 V DC power supply This voltage supply is fed to the Power Rail and hence to all the devices mounted on this rail Fuses in the power feed modules provide the group fusing 5 2 1 Construction of the Power Feed Module LED red Fault signal LED green Power Fine wire fuse Type T Figure 5 1 Front view of power feed module The presence of rated operating voltage is indicated by a green PWR LED on the front panel of the device The status of the fusing is signalled via a red fault LED 5 2 2 Setting the Mode of Operation of the Relay The response of the fuse is indicated via the energized relay in the setting on delivery In order to adjust the mode of operation of the relay first remove the narrow front panel using a suitable screwdriver Insert the screwdriver into one of the two cutouts and remove the front plate by careful leverage The cover of the left section can then be gently lifted away from the catches Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65
289. rl fuchs com 23 24 Remote Process Interface Product Description Integrated Signal Transfer and Mechanical Mounting Power Rail The Power Rail is available e as insert for the DIN rail according to DIN EN 50022 or e as insert for the 35 x 15 mm top hat rail Five conductors are integrated into the Power Rail They have the following functions e 24V DC voltage supply of the components snapped onto the rail conductor 1 and 2 e Transfer of the RPI internal communication bus conductor 3 and 5 e Transfer of the HART communication conductor 4 In this case K system modules with centralized fault indications must not be installed since they are likewise transferred via conductor 4 Communication Between the RPI Modules RPI uses an internal bus with a fixed transfer rate of 250 kbit s RPI allows up to 125 devices as bus stations The gateway calculates the current cycle time according to the stored configuration The time need is cal culated in such a way that low priority signals acyclic services can be transferred The RPI internal bus system has a redundant design and switches to redundant transmission in the event of failure Gateways Interface to an External Bus By means of an RPI internal bus all connected RPI devices communicate with the gateway which ex changes the process data with the plant control via a standard bus The plant can be both a process control system DCS and a programmable logic controller PLC
290. rmany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Dismantling and Disposal 9 Dismantling and Disposal Repackaging Where devices and components are to be stored for reuse at a future date they should be protected against shock loads and humidity The original packaging affords optimum protection Disposal Electronic scrap is special refuse Local regulations must be followed when disposing of elec O tronic components I The devices in the RPI system do not contain internal batteries which must be removed prior Note to disposal Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 181 10 10 1 10 2 10 3 10 3 1 182 Remote Process Interface Quick instructions APPENDIX Quick instructions Installation of the Software on your PC It is recommended that all Windows programs are closed prior to the installation Load the PACTware CD into your CD drive Start Setup exe on the installation disc by going to the Start menu and clicking on Run Enter the following line into the next window Drive letter setup exe e g e setup exe You can also select your disc drive by clicking Browse and then Se
291. rocess data input output data e Device parameters e Channel specific parameters e Device diagnostic information e Channel specific diagnostic information e Device command data area The applicable data areas and specific requirements of individual device types are explained below 4 1 5 1 Process Data The process data contains the binary or analogue input or output data of all the channels on the devices e g the value measured by a temperature converter This data depends on the RPI device type 4 1 5 2 Device Parameters The device parameters contain individual and detailed data for the relevant device e Device type device ID e Serial number software hardware revision number part number e Number of channels type and structure of the input output data e HART support 4 1 5 3 Channel Specific Parameters The channel specific parameters contain data which is specific to a measuring point This data can be indi vidually set when programming the RPI devices using the human machine interface or via the higher level control system e Measuring point description TAG No e Comment e Sensor type connection system e Comment e Measuring range e Damping e Lead short circuit llead breakage monitoring not on all devices e Low high signal warning low high signal alarm for analogue inputs e Input output status in the error case e Calibration of the measuring range e Linearization of measured value cold junction compensation on thermocoupl
292. rrent operating mode The operating modes can be identified from the table provided on the front panel A NORM Normal operation b ADR INT Assignment of device addresses internal bus C CHK INT Checking device addresses internal bus d ADR EXT Setting the gateway address external bus E ADR PAR Set the gateway address service interface F BAUD INT Set baud rate internal bus G BAUD PAR Set baud rate service interface H BAUD EXT Set baud rate external bus only MODBUS gateway PARAM EXT Set parameter values external bus only MODBUS gateway The first three digits displayed show the status addresses or parameters depending on the set operating mode a vd Addresses Operating mode Parameter Status Normal operation During normal operation the menu identifier A appears in the gateway LC display If a device error message is communicated via the internal bus the display shows the address of the faulty device and the error code alternately The table of error codes is given in Chapter 5 4 2 10 Alternately Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 15 5 4 2 1 5 4 2 2 5 4 2 3 5 4 2 4 5 4 2 5 76 Remote Process Interface Configuring and Commissioning the RPI System Allocatio
293. s The data for the selected devices is summarized in the following table Device designation KSD2 GW PRO PROFIBUS Gateway KSD2 TI Ex Temperature converter KSD2 CI S Ex H Transmitter power supply KSD2 BO Ex2 2 Solenoid driver KSD2 Bl Ex4 Isolated switch amplifier Sump Table 4 4 Exemplary calculation power consumption current requirement The RPI system has a power consumption of 116 80 W and a current demand of 5 84 A Taking account of a safety margin of 20 the power supply must be 7 0 A e Simple arrangement of the power supply two Power Rail segments with one 4 A power feed module each 2 power feed modules in sum e Redundant design of the power supply four Power Rail segments with two 2 A power feed modules each and an integrated decoupling diode 8 in sum e Redundant design with external decoupling diodes two Power Rail segments with two 4 A power feed modules each 4 in sum In this case it should be ensured that the current consumption for each Power Rail segment cannot ex ceed 4 A Determining the Power Supply Segments As shown in the previous chapter the power supply balance depending on the redundancy concept results in different numbers of Power Rail segments per gateway The number of segments is only limited by the maximum permissible length of the internal bus line The latter is 8 m and can be obtained by adding the lengths of the segments and the lengths of the wiring bet ween the power feed mod
294. s monitored for lead breakage The sensor lead is monitored for short circuits Copyright Pepperl Fuchs Printed in Germany 6 4 6 5 108 Remote Process Interface Parameter Assignment Measuring Range Start The start value needs to be entered in order to be able to scale the measured value End The end value needs to be entered in order to be able to scale the measured value Example The current range is 4 20 mA and the measuring range is 1 5 bar The measured value is transferred via the external bus with a factor of 100 i e for instance at 2 5 bar a value of 250 is transferred Output Malfunction Output Status By means of the settings As Input Maximum Minimumor Hold Last Value the signal transferred to the control system in the error case is determined according to the application For the setting As Input a value should be entered in the box on the right hand side Downloading Project Data into the Gateway Having configured the RPI system and generated the project offline on the PC the data is downloaded to the gateway The PC notebook and the gateway are connected as follows 1 The PC is connected to the RS232 service interface of the gateway via the RS232 serial interface and the K ADP2 adapter 2 The PC is connected to the RS485 service interface of the gateway via a plug in card with RS485 or via a RS232 RS485 converter and a K ADP4 adapter The adapter is not required if there is a fixed wirin
295. sing elements e g optical or mechanical Temperature Converters e KSD2 TI Ex e KSD2 TI Voltage Converter e KSD2 VI Gateways e KSD2 GW PRO e KSD2 GW PRO 485 e KSD2 GW2 PRO KSD2 GW MOD e KSD2 GW MOD 485 e KSD2 GW CN e KSD2 GW CN 485 e KSD2 GW MPL e KSD2 GW MPL 485 HART Modules e KFD2 HMM 16 e KSD2 HC 1 channel Universal Temperature Converter with Ex approval 1 channel Universal Temperature Converter 1 channel Voltage Converter with a voltage range of 0 2 10 V PROFIBUS DP Gateway with RS 232 service interface PROFIBUS DP Gateway with RS 485 service interface PROFIBUS DP V1 Gateway with RS 232 and RS 485 service interface and full transmission for HART Protocol MODBUS Gateway RTU with RS 232 service interface MODBUS Gateway RTU with RS 485 service interface ControlNet Gateway with RS 232 service interface ControlNet Gateway with RS 485 service interface MODBUS PLUS Gateway with RS 232 service interface MODBUS PLUS Gateway with RS 485 service interface HART Multiplexer Master HART Control Module Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 3 4 3 4 1 3 4 2 3 4 3 Remote Process Interface Product Description Commissioning Procedure for the RPI
296. sonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Configuring and Commissioning the RPI System 5 6 Configuration of RPI Devices with Automatic Address Assignment Using PAC Tware The parameter assignment of the RPI devices can be prepared offline during the planning phase of the RPI system see Chapter 6 O A detailed description of the software human machine interface PAC Tyure edition 2 can be Note obtained from the PACT zare edition 2 handbook The handbook is available for download on http Awww pepperl fuchs com pa accessories pactware main htm The RPI devices can be allocated to both the planned parameters and the RPI internal addresses during the mechanical layout of the system 5 6 1 Configuration via the Service Interface 1 Project the RPI system using the human machine interface PACTware edition 2 on the PC as des cribed in Chapter 4 Planning of the RPI System 2 Prepare the installation of the RPI system following the details given inChapter 4 Planning of the RPI System Mount the power feed modules and gateways at the appropriate positions on the Power Rails Keep the RPI devices ready but do not yet mount them on the Power Rail 3 Switch on the po
297. ss is shown on the gateway display 2 By determining and displaying the address which is held by a particular device Briefly depress the ADR button less than 3 s on the device that is to be identified The gateway display shows the address of the device On the device itself the green PWR LED flas hes Setting the Gateway Address on the External Bus On selecting operating mode d ADR EXT the currently set address appears in the display The address can be reset by means of the W and pushbuttons The set address is accepted on depressing the mode button for longer than 3 s Setting the Address of the RS 232 RS 485 Service Interface The RPI human machine interface supports the simultaneous connection of a PC to a number of gateways as a subordinate service level Up to 31 gateways can be managed and parameterised if the installed PC and the gateways operate via RS 485 interfaces On selecting the operating mode E ADR PAR the currently set address is shown in the display default 0 The address address range 0 31 can be reset using the W and buttons The address is accepted by depressing the mode button for longer than 3 s Transfer Rate of the Internal Bus The operating mode F BAUD INT shows the set baud rate of 250 kbit s of the internal bus Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 425355
298. st between the individual segments so that the end pieces of the Power Rail do not make contact with the neighbouring segment Join the individual Power Rail sections using a VE PR connection fitting see Figure Figure 4 9 A right hand and a left hand end contact should be used for the respective ends to allow the VE PR components to be mounted RPI devices can also be mounted over the connecting components so that no space is lost Having inserted the Power Rail into the top hat DIN rail the devices of the RPI system are simply snap ped onto the rail Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Planning of the RPI System 4 8 1 6 Accessories for Power Rail PR 05 4 8 1 7 End cap 1 conductor HART signal transmission 2 conductors for bus connection Power rail A for power supply Connectors for coupling the Figure 4 9 Assembly of the PR 05 Power Rail Combining the RPI System with Interface Modules from other Systems If interface functions are required in your application which are not available in the modular RPI system modules from other systems which can be rail mounted can also be installed Thus a unified mounting tech nique is achiev
299. station on the internal bus Device address indicates it is not included in the gateway configuration Incorrect device type Channel error e g lead breakage or short circuit of the signal circuit of the faulty device channel No see device LED o Device ininitialisation phase O O OZ OoOO yO o Devieeisbeingsimulted O O OoOO Redundant communication failure external communication Redundant communication failure user initiated Check sums of the parameter sets in the active and passive gateway are not the same Error Messages on the Display of the KSD2 GW2 Gateway o o ero Devmiss Devicenotavailable Ero Devnot conf Device not configured o E03 wobe Wrongdevice o Eno Devem Device causes enor oo E05 CE Channel causes error E06 inem Errori linearizatontae o E07 Addr Conti Two devices with same address E sm Device in simulation mode APPLERR INT _ internalinterface oo O O C CNAA CANH CAN Bus connection shorkorot CAN_L FAULT canl CAN Bus connection lead breakage Allother NOT DEF Not defined or supporied FucDag SHoRToRC sc SSCS l OOo E LO ALM IOWRN Lowsignal Waming Coo f HAM HWRN Hoh signa Warming 00am OAM Lowsignal Alarm HAMAM HAM High signal Aam i eRe o o o orane oo G E All other NOT DEF _ Not defined or supported Subject to reasonable modifications due to
300. system is automatically signalled to the control system Redundant External Bus System The external bus system can also be provided with a redundant layout by installing a second gateway In this case the configuration data is replicated in the second gateway Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Quick instructions 10 12 Construction of a Redundant External Bus System with Gateways 1 Project with redundant gateway Build up your project in the usual way with a gateway using the PAC Tware human machine inter face In the project window highlight HOST IBM PC its symbol is on a blue background Now high light your gateway in the list of devices and select Paste In the project window highlight the redundant gateway its symbol is on a blue background Highlight your redundant gateway in the list of devices and select Paste Go back to the project window and highlight the redundant gateway its symbol is on a blue back ground Now add all the required RPI devices until the project tree is complete On adding a device PACT ware automatically assigns an address for the RPI internal CAN bus This appears on the left of the compon
301. system with the PACTware edition 2 or the K SK1 human machine interface To do this the PC is connected to the gateway via the service interface If an RS 232 interface is available connection to the PC can be made via the K ADP2 adapter A jack socket is provided on the front of the gateway for this purpose If the PC is to remain connected to the RPI system as a configuring and monitoring system it is recommended that connection is made via the plug in screw terminals 7 8 and 9 using the K ADP4 adapter On the KSD2 GW MOD 485 gateway with the RS 485 program interface only the terminal connection is available Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface The complete configuration of the RPI system can also be undertaken from the control system via the Mod bus providing that the control system supports this O The jack socket on the front and the screw terminal connection for the RS 232 link cannot be il used simultaneously Note Connection to the 24 V DC supply and to the internal CAN bus is achieved via the Power Rail The cable connections are made via self opening screw terminals max core cross section 1 x 2 5 mm for rigid cables or 2 x 1 5 mm for
302. t is provided on the front of the gateway for this purpose f the PC is to remain connected to the RPI system as a parameterising and monitoring device itis recommended that connection is made via the plug in screw terminals 7 8 and 9 which are in parallel with the jack socket On the KSD2 GW MOD 485 gateway with the RS 485 interface only the terminal connection is available The complete configuration of the RPI system can also be undertaken from the control system via the Mod bus providing that the control system supports this O The jack socket on the front and the screw terminal connection for the RS 232 link cannot be il used simultaneously Note Connection to the 24 V DC supply and to the internal bus is achieved via the Power Rail The cable connections are made via self opening screw terminals max core cross section 1 x 2 5 mm for rigid cables or 2 x 1 5 mm for flexible cables with plastic wire end ferrule The screw terminal blocks on the device can be removed for ease of connection Mount the gateway on the Power Rail and connect the Modbus cable and if necessary the RS232 RS485 cable The connection plan for the gateway can be obtained from the current issue of the Interface DIN Rail Hou sing catalogue O The number of stations on one RS485 interface Modbus interface such as the RS485 service il interface is a maximum of 31 as standard Note The maximum length of lead on a bus segment is effectively determi
303. t E Analogue presentation if no OK error occurs without fault A008 14 45 Al 1 Esc Ch 1 Error f Up Down Up Down A012 10 05 Err 2 Ch 2 4 i Up Down Up Down Y A021 5 05 Device button Err 5 Ch3 is actuated i Up Down Binary presentation OK A109 O BI 4 Esc Ch 1 Ch 2 lt e h Figure 5 9 Monitor menu For binary channels the states appear as 0 or 1 in the display If the transferred measured value of analogue channels is outside the number range of 999 to 9999 OFL is indicated The PWR LED flashes on the RPI device whose measured value is shown on the display 5 4 3 5 Checking the Device Addresses on the Internal Bus There are two principal ways of determining the address which is held by a particular RPI device 1 By selecting the device in the Monitor menu of the gateway On the RPI device itself the green PWR LED flashes 2 By briefly less than 3 s depressing the ADR button of the device The gateway should be in the Run or in the Monitor menu The gateway display shows the address of the device and the device type Now the gateway is in the Monitor menu and should be reset to normal mode Run by means of the Esc button The green PWR LED flashes on the device Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet htt
304. t devices 1 is reserved for the gateway 2 for the redundant gateway The only addresses displayed are those not already assigned within the system An address is accepted by depressing the ADR button on the device for a longer period The green PWR LED on the device flashes for a brief period Brief flashing of the red COM LED is irrelevant as is the error message on the gateway dis play which indicates that the device is addressed but has not yet been accepted into the gateway con figuration Now mount the next device select the appropriate address on the gateway using the or but tons etc Repeat this procedure until all the devices have been installed and assigned addresses It is important that the devices are mounted and addressed one after the other otherwise the gateway cannot build up the connection to each device As soon as a device is snapped on the red COM LED on the gateway goes out if not depress the Mode button for 3 5 secs in Mode F The green PWR LED on the device illuminates and the red ERR Error LED flashes 3 Conflicting addresses and address 0 It is possible to mount a device B that already has another address provided that a different device A is notin operation on the gateway with the same address If it is device A has to be removed from the mounting rail and device B assigned the correct address following the procedure given above Dev
305. t of the gateway s and other devices O il We recommend to allow for a safety margin of 20 in the power supply balance Note Current Power 20 V The nominal current for the conductors integrated in the Power Rail is 4 A This value must not be exceeded Attention The power supply modules provide a maximum of 4 A or 2 Aon the versions for redundant power supply The maximum current consumption of all RPI devices and gateways in a segment must not exceed the available output currents of the power feed modules If the current consumption of all devices is higher than the output current of the power feed module used a number of Power Rail segments with one power supply module each have to be installed The RPI internal bus can be daisy chained from the segment with the gateway to all other segments Exemplary calculation An RPI system consists of the following modules 1 KSD2 GW PRO 10 KSD2 TI Ex 20 KSD2 Cl S Ex 10 KSD2 BO Ex2 45 KSD2 Bl Ex4 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 4 7 6 4 7 7 Remote Process Interface Planning of the RPI System Detailed information on the power consumption and the current demand of the individual modules is provi ded in the data sheet
306. t save as The file name for your project can be freely selected but the file extension is always PW 10 4 Error Messages 1 RPI human machine interface error messages The COM port you wish to use to establish a connection is either not available or is already being used for another purpose Adapt the COM port settings for your project on the human machine interface to the COM port settings on your PC It has not been possible to establish a connection with the device If a connection has not been established you should check the cable connection with the gateway pa rameterizing interface the COM ports COM 1 to COM 4 selected for adaptation to your PC using the RPI human machine interface the compatibility of the baud rate of the parameterizing interface on the gateway in mode G with the setting of the COM port on the human machine interface and the agree ment between the address of the parameterizing interface on the gateway in mode Eand that on the human machine interface lt 0 gt 2 Error messages on the gateway LC display Now press the Mode button on the priority gateway repeatedly until A normal operation appears in the right hand position on the gateway display If the left hand positions on the display are empty the system is in normal operation lf a fault occurs the address of the faulty device appears on the left hand side adjacent to the A sym bol The display then cycles
307. t values are transferred with a factor of 10 whereas current input and output values are transferred with a factor of 100 As a result the transfer of the numerical value of 1560 leads to a measured value of 156 0 C for temperature measurements or 15 6 mA for mA measurements Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 111 112 Remote Process Interface Integration into the Higher Level Bus System Status Information of Process Data Profibus Modbus RTU Modbus Plus and ControlNet can also transfer the status of process values Depending on the status the transferred value is either reprocessed or rejected The space occupied by the status information per channel of a device is 1 byte for the PROFIBUS protocol 1 register for Modbus RTU 1 word for Modbus Plus and 1 word for ControlNet 1 During the transfer of analogue values bit O of the low byte Dat is always set to 0 Binary signals are trans ferred via bit O of the low byte Dat Bits GW1 and GW2 are reserved for limit value monitoring CD1 to CD3 code any errors which have occurred Q1 and Q2 provide information on the signal quality The messages shown in the table below are generated instantaneously Meaning iowa Jew ovs coz oot az Jar a Good oo d S S o S S d o oo No
308. ta is represented in the individual registers are given in 7 3 6 to 7 3 13 Section 7 3 16 provides a tabular summary of all the equations Detailed information on the Modbus protocol can be obtained from the Modicon modbus protocol refe rence guide PI MBUS 300 Rev D A register is 16 bits long In this handbook the data is represented as follows Register higher byte Register lower byte MSB LSB MSB LSB Bi 15 Bit 14 Be 13 Bit 12 Bit 11 Bit 10 Bt9 BRS Bi7 Bitt BRO Reading Binary Input Data without Status The expression binary input data is intended to imply the switching states of switches and proximity sen sors The KSD2 GW MOD and KSD2 GW MOD 485 provides the user with this data both channel based and device based In the case of the channel based representation each channel of a device is presented in an individual register This type of representation is to be preferred if only one channel is to be read In the de vice based type of representation up to four RPI devices can be represented in one register This type of representation enables the data of many RPI devices to be transmitted with relatively small Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 e Internet http Avww pepperl fuchs com 139 140 Remote Process Interface amounts of data The pre
309. tandard test connectors of HART or SMART hand held terminals Order codes KF STP BU blue Ex side KF STP GN green non Ex side 21 15 16 Figure 4 13 Terminal block KF STP BU KF STP GN O The HART and SMART compatible RPI devices KSD2 Cl S Ex KSD2 Cl S Ex2 H KSD2 CO S Ex and KSD2 CO S Ex2 H are equipped as standard with terminal block KF STP BU KF STP GN Note Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 58 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Planning of the RPI System Terminal block with cold junction compensation Removable terminal block with integrated temperature sensors for cold junction compensation for the con nection of thermocouples to the KSD2 TI Ex universal temperature converter Order codes K CJC BU blueEx side K CJC GN greennon Ex side Device connectors with sensors Potted Pt100 RTD in a 2 wire configuation Potted Pt100 RTD in a 2 wire configuation Figure 4 14 K CJC Terminal block with cold junction compensation Dummy housing The KFDO LGH dummy housing is a module used for laying cables An RPI system can be completely prewired without mounting the actual module The clarity of the installa tion and compactness in the control cabinet are cons
310. tcertain CF tf aen Se Good no error Good no error error Measurement range exceeded fallen short Simulated measured value sd measured value 14110 4 014 S a Configuration error o o ili lolo RPld vieerr o i oli olo Fielddeviceeror S OO OO tT OO OO No communication astgoodvalue 1 0 1 1 0 0 Nolimitvauereached S C lLowerlimit value fallenshot o 1 T lo Upper imit vae exceeded 1 o l lo Operation with a Redundant Gateway Operation with redundant gateways increases the availability of the system The gateway that is active in normal operation must have the RPI address 1 whilst the redundant gateway must have the RPI address 2 The prerequisite for the operation of a system with a redundant gateway is that the configuration data for each RPI device is stored in a file in the current project directory The following describes the installation procedure that is necessary in the case of a gateway newly deliver ed from the manufacturer If this not the case connect the Modbus gateway alone to a 24 V DC supply and depress the mode button in mode A for KSD2 GW for longer than 3 s or depress the OK button in the Teach in service menu for KSD2 GW2 This causes the current configuration here no device to be taught in In the following it is assumed that the RPI devices are pre configured and mounted on the Power Rail If this is not the case
311. tcoucccces detect cat a are aa a aa a aAa a A Opening a Pro CCI eee ee mene ee eee eee cree ee eee E e REE a a O NOW PTOCCIE sarcicepie sticrnssceeiyatecierte teria E I S a a aa Adding COmMmpPON N S sicdsetecinendasaetauctsncetcasscnvacen aan a a eio ogi sa oO Deleting COMPONENTS cee ce csesccsenesceceseeceanscecuaaeeceaceeeceauececusaeseaececaeeaeeseaeeceauseeeeaeeseeseseseeansessssetesenesesss O ParameteriZing Individual Components cccceeecececeececeeeensoeecesanenseaeaeeanensnsaeanseseeeneeonnseeenesesseseneeeees OL Parameters of the COM Drivers c cccccccececesceceeseeceececeneceesceaeacecseseaueeceaeeseaseeseaeesesseeaesesaseetaseessaseesseeesss OL APL ENA MC ACS si ctecincenttaedscnncuaisrcocieaceaacteneasdecarulecabuanectunchivasetncaeeecactenanidaacnubacttremerent heute erouseteasenrdeanatantdeentesentsierton 97 PARE FOO C OLOIYOT seron a E E E E E AE 97 Device Type Managers for Non RPI Devices cccccccccsseecceeeecceseeeceeeeeceeeeecaueeeseuseesaeeeseeeesaueeesaseesaaeeesaueeesansessags 98 Gateway Parameters cccccecececesceceeneceseeaeecseceeeceaeeseausaeseaneececeeeseaeseeauaaessaneaeeceaeseeanseesnenessanssesssessessseess OO OD SD peatecte ceca ce rcecte E nn acervsaeec sae E E E 98 MODBUS PIUS serea E Serene cya dere arena ast ant n tna osc ros arf iouisunnc oanstnrc ossioaioeabamebantncn ste amaceuaneeoseaeeds 98 PROFIBUS DP and DP VT sonreir e Qeatioseanoutasananciweassaunnacobdeinatisastieci
312. te 1 Not used Status Register address 2 Data byte 4 Data byte 3 Writing reading analogue output data 2 channel devices All measured values from 1 or 2 channelled devices are represented in this area as a function of the current RPI address The register addresses can be obtained from the following equations Data format Register address Signed integer 3 RPI address 3 5641 Floating point 5 RPI address 3 7567 3 registers have to be read in the signed integer format The data is constructed as follows Register address 1 Register address Channel 1 Status Channel 2 Status Channel 1 Register address 2 Channel 2 5 registers have to be read in floating point format These are constructed as follows Register address 1 Register address Channel 1 Data word 1 Status Channel 2 Status Channel 1 Register addresst 3 Register addresst 2 Channel 2 Data word 1 Channel 1 Data word 2 Register address 4 Channel 2 Data word 2 Writing reading analogue output data 3 channel devices All measured values from 1 2 and 3 channelled devices are represented in this area as a function of the current RPI address The register addresses can be obtained from the following equations Data format Register address Signed integer 6 RPI address 3 2072 Floating point 8 RPI address 3 536 If all the information from a device is to be read in signed integer format 6 regis
313. te case with the input data On a number of RPI modules 1 8 per module the data is arranged module by module in ascending order according to the RPI bus address If a module has several channels the data is arranged in ascending order by channel The arrangement of binary data within a byte is in ascending order from bit 0 Data types The following data types are used to represent input and output data e boolean bit by bit data organisation e signed integer 2 byte integer format with sign e FLOAT 4 byte floating point to IEEE 754 standard short real number Data structure The structure of the data bytes transmitted is given below The following abbreviations are used CH channel channel number of an RPI device device number of the RPI device within a module n 1 8 Binary input and output data without status 1 channel modules Module types n x 1DI n x 1DO MSB LSB ojojo o ns 1111 1 1 SF FN SS D4 D3 D2 D1 2 channel modules Module types n x 2DI nx 2DO MSB LSB 2 1 21 12 1 2 1 hau S a D4 D3 D2 D1 4 channel modules Module types n x 4DI MSB 1 Byte LSB MSB 2 Byte LSB 4 3 2 1 4 3 2 1 413 2 1 41 31 2 1 p S o S G Xe e D4 D3 D2 D1 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 122 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com
314. ter ii face 5 6 2 1 Gateway Type KSD2 GW Set operating mode A on the gateway and depress the mode button for longer than 3 seconds All new settings of the RPI devices are now stored in the gateway 5 6 2 2 Gateway Type KSD2 GW2 Select the Service menu by simultaneously depressing the Esc and OK button on the gateway The data from the RPI devices are transferred to the gateway using the Teach in service menu Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 91 5 6 3 5 7 5 7 1 5 7 2 5 8 5 9 92 Remote Process Interface Configuring and Commissioning the RPI System Checking the Configuration and Parameter Assignment After the configuration and parameterization data has been transmitted possible errors are indicated on the LEDs and on the display of the gateway A verification of the RPI system can be carried out by means of the diagnostic and simulation functions provided by PAC Tare The individual error messages of the RPI modules are described in Chapter Monitoring Simulating Measured Values and Error Handling and the error messages are desribed in Chapter 11 RPI System Error Messages Online Commissioning Online commissioning implies that the PC with the human machine interface
315. ters have to be read Access to one channel can be achieved by adding the term 2 Channel number 1 The data is constructed as fol lows Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Register addresst 1 Register address Oooo Chaneli Status Channel 4s Register address 3 Register address 2 o Chamel2 Status Channel2 sid Register address 5 Register address 4 Channel 3 Status Channel 3 In the floating point format 8 registers have to be read These are constructed as follows Register address 1 Register address Register addresst3 Register address 2 Chamnel1 Datawora2 S sSCharnel 1 Dataword1 sid Register addresst5 Register address 4 Chamel 2 Dataword1 Channel2 Dataword1 sid Register address 7 Register addresst 6 Channel 3 Data word 2 Channel 3 Data word 1 7 3 13 Special case Holding Register O This section deals with the special case in which the host PLC or control system does not sup il port access to the input register Table 04 In this case the analogue input data is imaged in holding registers Table 03 Note O In order to have access to the analogue input data the register address O Ta
316. the ControlNet connection The ControlNet address is set by the two rotary switches Possible addresses are 1 through 99 The RPI service interface can be either an RS 232 KSD2 GW CN or an RS 485 interface KSD2 GW MPL 485 it is used to configure the RPI system with the PACT zare edition 2 human machine interface To do this the PC is connected to the gateway via the service interface Ifan RS 232 interface is available connection to the PC can be made via the K ADP2 adapter A jack socket is provided on the front of the gateway for this purpose If the PC is to remain permanently connected to the RPI system as a configuring and monitoring system it is recommended that connection is made via the Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 169 170 Remote Process Interface plug in screw terminals 7 8 and 9 which are in parallel with the jack socket O The jack socket on the front and the screw terminal connection for the RS 232 link cannot be ial used simultaneously Note On the KSD2 GW MOD 485 gateway with the RS 485 service interface only the terminal connection is available Connection to the 24 V DC supply and to the RPI internal bus is achieved via the Power Rail The cable connections are made via self opening screw terminals
317. the following description means the software module that communicates with PROFI BUS DP Use the status transmission for all or none of the devices depending on the parameterization of the gateway Attention Always use either INT or FLOAT as a data format for analogue values i When selecting the RPI devices the following PROFIBUS specific details should be considered If you wish to deactivate status signals such as lead breakage for individual devices you can do so by set ting the device data in the parameterization software accordingly The assignment of the RPI devices to the individual DP slave module addresses is carried out automatically by the gateway but can also be changed by a class 2 DP master device using the Set_Slave_Add function A new DP slave module is always installed in the plug in station with the lowest free DP slave mo dule address If no more than 64 RPI devices are connected to the gateway each device is assigned its own DP slave module address RPI Bus Address DP Slave Module Address 10 O KBA 2 20 21 40 A terminal strip for marshalling signals must be provided for conventional MSR systems see Chapter 6 Commissioning This can be done on the software side by assigning the RPI module a different RPI bus address This assignment is no longer possible if there are more than 64 RPI devices on the gateway In this case up to eight identical RPI devices are assigned to a DP slave module by means of the
318. the input registers of a Modbus station by PLC s or process control systems In exceptional cases it may be that control of access to the input register is not supported In this case the corrrect register addresses can be obtained from Section 7 3 13 Three error messages are generated for the binary data the significance of which is given in the following table Meaning ewe Gwi cos coz cot a2 at dat Internal memory or interface error ce Nocommunication 4A OO 4 4 Of Fielddeviceeror SCC Of OO 4 fof The first two lines indicate an error in the RPI device The third line indicates a lead breakage or short circuit where this information is only generated if the option s of lead breakage monitoring or short circuit monito ring are activated on the device Further information can be obtained from Part B of this handbook RPI devices with a maximum of 4 channels with status 2 registers per RPI device The data from 1 2 or 4 channel devices are filed in this area 2 registers must be read in order to obtain the complete information for all channels The register address is obtained from the following equation Address 2 RPI address 3 3587 The data is represented as follows Register address High byte Channel 2 Low byte Channel 1 Register address 1 High byte Channel 4 Low byte Channel 3 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in G
319. then when the active gateway has been installed step 1 the RPI devices must be addres sed The information required for this procedure is given in Chapter 5 Configuration and in Chapter 6 Pa rameter Assignment Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Integration into the Higher Level Bus System The following sequence should then be carried out 1 Mount a gateway on the Power Rail and set the RPI address of this gateway to 1 active gateway 2 Teach in the current configuration via mode A or via the Teach in menu 3 Load the project into the gateway download using the PAC Tare software or transmit the configu ration and parameterization data by means of Profibus DP V1 as described in Chapter 6 4 Downloa ding Project Data into the Gateway 4 Mount the 2nd gateway on the Power Rail and set the RPI address of this gateway to 2 redundant gateway 5 Connect the PC to the redundant gateway and then repeat steps 2 and 3 for the redundant gateway O The active and the redundant gateway must receive different addresses for the PROFIBUS Ll Note If the project has been downloaded into the redundant gateway the system is ready for redu
320. tions due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 6 2 1 6 2 2 6 2 3 Remote Process Interface Parameter Assignment Opening a Project An existing project is opened using the menu item lt Open file gt in the menu bar or the tool bar button lt 7 in the tool bar New Project Open a new project using the menu item lt New gt in the menu bar and then store it under the name you have chosen The project is structured as a tree based on the preset entry HOST IBM PC in the following order of suc cession 1 COM driver RPI Serial interface 2 First gateway 3 Added to the first gateway optionally second gateway for redundant communication with the control system 4 RPI devices added to the first gateway Next gateway for additional RPI string added to COM driver gateways and devices 6 Next COM driver added to HOST IBM PC e g for HART communication or connection of non RP devices on Adding Components There are three ways to edit a project in the project window 1 Click onto the desired position in the project tree using the right mouse button and select the menu item lt Add device gt 2 Click onto the desired position in the project tree using the left mouse button and then onto lt Add
321. tup exe Click OK to confirm your entry Now the setup program starts The human machine interface is provided with a context sensitive help menu to answer your questions Voltage supply for the RPI system The supply voltage 20 to 30 V DC or 230V AC is connected to the power feed modules that make a con nection to the Power Rail The devices will be plugged onto the rail later when they will have been configu red and the parameters will have been set Power will now be supplied automatically and the green PWR LED s on the devices will light Configuration and Parameter Assignment of the RPI System The two alternative methods of configuring the RPI system are described in the following Offline Configuration and Downloading to the Devices The project is set up offline using the PACTware and stored in the PC On Download the data in all con figuration files relating to the project are stored in the individual devices 1 Start PACT are edition 2 Start the PACTare human machine interface on your PC When working with PAC Tare you can chan ge decisions you have made later on After the program start the main window opens The project window displays and installs the RPI sy stem and the various components and drivers The edit window displays the various menus that are required for the project such as device catalogue register cards for the parameter assignment menus for diagnosis measurement values and simul
322. uchs Printed in Germany 81 5 4 3 3 5 4 3 4 82 Remote Process Interface Configuring and Commissioning the RPI System Fault If device error messages are communicated via the internal bus the display shows the device with the lo west address and its error code The addresses and error codes of other faulty devices can be shown in the display using the Up and Down buttons The error codes have the following meanings Error code Significance 01 A device included in the gateway configuration does not exist as a station on the internal bus Device address indicates it is not included in the gateway configuration 02 Device address indicates it is not included in the gateway configuration 03 Incorrect device type 04 Channel error e g lead breakage or short circuit of the signal circuit of the faulty device for channel No see device LED Device in initialisation phase 0 Addressing conflict Device is being simulated Redundant communication failure internal communication Redundant communication failure external communication Loss of redundancy user initiated Check sums of the parameter sets in the active and passive gateway are not the same 7 81 82 83 84 O It is recommended that on the occurrence of an error message the Up and Down buttons are always pressed in order to be able to detect errors in other devices The RPI system can also be operated without an external bus conne
323. uchs Group Tel Germany 49 621 776 0 e USA 1 330 4253555 Singapore 65 67799091 Internet http Awww pepperl fuchs com 15 1 3 1 4 16 Remote Process Interface The Remote Process Interface RPI in Brief Notes on Using the Handbook In order to enable you to familiarize yourself quickly with the RPI system and to have a rapid access to the necessary pieces of information this handbook provides a detailed table of contents The following overview provides a short outline of the topics dealt with in the individual chapters Operating Instructions in Brief Summarizes all important steps of a commissioning procedure and should be used by experienced users as a checklist for rapid commissioning by means of the PACT are human machine interface Chapter 1 Introduction explains the principle of operation of the RPI and provides an overview of the structure and aim of the hand book Chapter 2 Safety explains the symbols used in the document informs the user about potential dangers the intended use of the device and its use within Zone 2 of the hazardous area Chapter 3 Product Description describes the structure and the individual components of the RPI system in detail Chapter 4 Planning of the RPI System shows the planning procedure in chronological order It provides the information required for a mechanical and electronic assembly of the system and explains methods for determining the type and number of RPI
324. ules Therefore in constructing the segments and the RPI modules it should be ensured that the separation of the power supply modules is as small as possible Ifa number of power supply segments are required on one mounting rail then the Power Rail sections are not connected with each other at the segment boundaries but are separated from each other by a distance of at least 1 mm One possibility of arranging the mounting rails and connecting the power supply segments is represented in Figure 4 16 on page 61 of this system manual O In forming the segments without a redundant supply it must be considered that if the fuse ope il rates all interfaces of the segment in question fail if the system has no redundancy It must be ensured that in this case a dangerous situation does not arise in the system Note Establishing the Type and Number of the Power Supply Modules When planning a redundant power supply the following should be considered e In the event of the failure of a power supply module the complete segment must be supplied via the intact power supply module The power supply modules should be laid out accordingly e Furthermore it must not be the case that in the event of failure a flow of power from the intact to the defective power supply unit takes place This flow of energy is prevented by decoupled diodes Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pep
325. ure 8 5 Simulation of device and system specific error messages The options Device System andChannel specific enable you to simulate the error messages Mark the check box of the signal whose status you want to change A checked box means that the according error signal is set 2 lt 1007 gt KSD2 TI EX Simulation E j ioj xj Short Circuit Lead Breakage Low Singal Waming High Signal Wamung Low Signal Alarm High Signal Alarm Signal under Measuring Range Signal over Measunng Range OoOocoooo0o9o EE ee ee I lActivate simulation Channel specilic ES Gove Figure 8 6 Simulation of channel specific messages If you choose Process Value you can simulate the state of the device inputs and outputs For binary de vices you simply check the box beside the LED of the channel whose state you want to change With ana logue devices you will find a text box under the bar graph to enter the desired value 007p KSD2 TI EX Simulation lt 006 gt K5D2 B0 Ex2 2 H Simulation oj x Process value channel 1 Process value Kanal 1 Ta eo Kanal PLT Stelle Status 1 Fo 2 E 3 E I Activate simulation Process value o IY Activate simulation Process value Y oO ep H Close Figure 8 7 Simulation of process values Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330
326. ut only if you have a PC connected to the RPI hardware an established communication connection and selected a de vice If the menu Display or the button i Monitor is not available check the communication and select the device to be monitored Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface K SK1 fj Pepper Fuchs K 55 1 7 MON 6 Mebstelle Z KS02 Tl Ex File Restat Display Time Tick analysis Retum a MON 13 KS Fa ensued Vale a i Paramettation of a KSDZBIEKZ COM fees 73a The big window shows a window for an analogue device the small window is an example of a binery device If you chose to monitor an analogue device you can set the type of display To see only the trend graph deselect display bar graph S MON 6 Hebstelle 2 KSD2 TI Ex Measured Value Trend l GEO If you need further help on the content of the windows and the menu bar please use the online help 12 3 9 1 Ending the monitoring All windows can be closed by menu commands Some windows may use the Back Close or Back Back to Main Menu command others Return Return to Main Menu Also some of the windows may have an end butto
327. ve mode Operation on the Modbus The Modbus is a register orientated bus system This means that the data is automatically stored in a me mory area the so called registers of the Modbus gateway The user can access specific data by reading the se registers and set targeted outputs by writing to them These registers are organised into four tables Table Contents 1 Binary outputs Binary inputs Analogue outputs acyclic parameter channels Analogue inputs DEVICE_TYP and DEVICE_ID The Modbus offers two transfer modes for data exchange the ASCII and the RTU mode O The KSD2 GW MOD and KSD2 GW MOD 485 gateways only support the RTU mode Il Note Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 7 3 5 Remote Process Interface The Modbus master informs the slave via the function code which table should be interrogated and whether values are to be read or written The following table shows which function codes are supported by the Mod bus gateway 01 Read Coil Status Read binary outputs Read Input Status Read binary inputs Read Holding Register Read from write read registers e g analogue outputs acyclic parameter channels Read Input Register Read from read registers e g analogue
328. ves you a choice of suitable devices BUTTONS MIDDLE You can copy cut or delete selected items by clicking onto the buttons If they are not available they are shaded in gray The direction indicated by lt lt and gt gt means that the window in this direction is affected 12 3 4 2 Selecting the active part of the window L Click into the window part you want to activate E Press tab to switch between the two window parts A blue ribbon marks the selected item in the active part of the window SELECTING ITEMS The selected item is highlighted in yellow and blue To select an other item 0 click onto the new item a move the marker with the cursor keys The cursor up and the cursor left move the marker up the cursor down and the cursor down move it downwards J Toselect more than one icon at the same time press down the shift key or the control key feo With the shift key you select the whole range between the already selected and the new sel ected item Using the control key let s you choose item by item USING THE BUTTONS To activate any button WE click onto the button iy use the key the underlined character 12 3 4 3 Getting help If you need additional help you can select Help Contents or search for help on 12 3 4 4 Undoing changes There is no undo function available Please make all changes to your project carefully and use the save function frequently This helps you to a
329. vice in front of the selected item append will add it behind Pepperl Fuchs K 5K Edit Project L Project Edit Clipboard Options Retum Help lej xj 3 Host IBM PC or compatible FC COM 1 COM Port API LEB lt 002 1 KSD2 GW PRO 3 HAX KSD2 TI Ex 3 XXX KSD2 CI Ex M 3 MODUL KSD2 BI Ex A 3 MODUL KSD2 BI Ex4 C 31 MUDUL KSD2 B1 4 3 XX KSD2 BO Ex 3 XXX KSD2 Cl 5 Ex 2 XX KSDI CN Fs KO BIO KSD2 C0 S Ex C 2 MODUL KSD2 RO Ex2 Devine Tyne l4 Lhannets binary input part number Devine Type HPI Gateway tor PRUFIBUS DP DIN E Vendor Feppertt uche Vandor Pepperl t uche Set the structure of a project O CoM hees ea A new device is pasted The new device is right in front of the seleced one Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 204 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface K SK1 Pepperl Fuchs K 56 Edit Project ky Project Edit Clipboard Options Retum Help e x oject LEER_PAJ Cliphoard Device List a Host IBM PC or compatible COM 1 COM Port NPI lt 00 gt 1 KSD2 GW PRO A 3 XKX KSD2 TI Ex ae 3 AAA KSD2 Cl Ex 3 MODUL K5SD2 BI Ex2 3 MODUL KSD2 BI Ex4 C 131 MUDUL KSD2 BI 4 BIAK KSD2 80 E 3 x KSD2
330. void undesired additional work 12 3 4 5 Adding a device Select the place in the current project where you want to add the new device or branch by selecting a device before or after that desired place Then select the device you want to add in the clipboard view Press paste if you want to add it before the selected device or append if you want to add it behind the selected device position It is also possible to choose Edit Paste After you added the device s you should configure it Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com 203 Remote Process Interface K SK1 Pepperl Fuchs K 56 Edit Project i Project Edit Clipboard Options Retum Help x Cliphoard Device List LI COM 1 COM Port NPI LT lt 00 gt 1 KSD2 GW PRO 3 XXX KSD2 TI Ex 3 AAA KSD2 60 Ex Copy gt gt 3 AXA RSD2 Cl Ex 3 MODUL KSD2 61 Ex Hm Cut gt gt Delete 3 AAA KSD2 Cl S Ex Contig A SX KSD CN F x Devine Tune 4 Lhannels binary input part number Devine Tune Digtal output part number 35355 Vendor Pepper tuchs Vendor Pepperl t uchs Set the structure of a project COM fse ese Starting point The selected device is highlighted Paste and Append are relative to the selected item Paste will add the new de
331. ween the safe and the hazardous areas Non Ex modules are also available Special modules for direct connection of transmitters temperature sen sors valves contacts and inductive proximity switches Bi directional transmission for HART signals Integrated lead breakage and short circuit monitoring Integration of instrumentation functions such as alarm and error limit values calibration linearisation etc Diagnosis and error messages via LEDs and communication via the inter nal bus to the gateway and via the external bus to the DCS or PLC or via the service interface to the PC Copyright Pepperl Fuchs Printed in Germany Date of issue 05 27 03 Date of issue 05 27 03 Remote Process Interface Product Description 3 2 2 Flexibility by Virtue of Modularity Device combinations Number of RPI bus sta RPI modules having various functions can be arbitrarily attached to the Power Rail assembly All modules can easily be snapped on the Power Rail Marshalling of the signal current circuits is not necessary Combinations with devices of the Pepperl Fuchs K system are possible Up to 125 RPI devices on one RPI line tions e 1 active RPI gateway per RPI line e 1 redundant passive gateway per RPI line option e Larger assemblies can be achieved by coupling a number of RPI bus lines together on the external bus 3 2 3 Internal and external communication Transfer rate internal Transfer rate external Transfer rate o
332. wer supply for the RPI system see Chapter 5 2 Power Supply 4 Configure the gateways as described in Chapter 5 4 2 for the KSD2 GW type and in Chapter 5 4 3 for the KSD2 GW2 type 5 Connect your PC with PACTware edition 2 and your configured RPI system on it to the gateway Please use adapter K ADP2 for RS232 or K ADP4 for RS485 depending on the service interface After that you should download the offline generated project to the gateway 6 Snap the individual RPI devices onto the Power Rail one after the other in ascending order of address according to your project In so doing the device is allocated an RPI internal address and the related parameter data is downloaded to the device Make sure that you commence with the RPI device with the lowest RPI address that the devices have RPI address 0 prior to commissioning 5 6 2 Acceptance of the Configuration and Parameter Assignment of an Existing RPI System In case your RPI system is already configured or in operation the parameter data of the RPI devices can be transferred to the gateway and further on to the PACTware human machine interface This is helpful for changing RPI devices replacing a gateway or documenting the system using the PACT ware human machine interface O il Be sure to keep track of the documentation of your project on the human machine interface ua This can be done by using the Project upload function of thePAC Tare human machine in
333. ww pepperl fuchs com Note All products are developed and produced in accordance with the relevant European standards and directi ves The manufacturer of the product Pepperl Fuchs GmbH in 68307 Mannheim Germany has a certified qua lity assurance system in accordance with ISO 9001 ce i ISO9001 Marking The most important information from the data sheet can be found on the left housing side of the devices as listed below Manufacturer Pepperl Fuchs GmbH Device type with part number Marking in accordance with EC Type Examination Certificate Device connection Terminal assignment with the most important nominal values of the inputs and outputs not available for every device Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of issue 05 27 03 Date of issue 05 27 03 3 1 3 1 1 Remote Process Interface Product Description Product Description System Structure and Principle of Operation The Remote Process Interface RPI is an interface system for conditioning conventional control signals and signals from and to sensors actuators and field devices on one side and a bus system on the other side The connection via a bus to the process control system or a programmable logic controller is carried out by means o
334. ystem Structure and Prin ciple of Operation for further details Note Availability Functional Integrity and Function Monitoring During the development of the Remote Process Interface we directed our special attention to electrical safe ty system availability as well as functionality of the system e Redundant layout of the internal bus system e The use of two gateways per RPI bus line and two external bus branches allows a completely redundant layout of the system e Redundant layout of the power supply with two power feed modules e Lead breakage and short circuit monitoring of the signal circuits by means of the RPI devices e Error and status indication via LEDs on the front panel of all devices e In addition to an external bus interface the gateway allows the connection of a PC or notebook via ser vice interface RS232 or RS485 A PC and an appropriate engineering tool constitute convenient tools for configuration parameter assignment simulation test and diagnosis purposes e Configuration parameter assignment simulation test and diagnosis can also be carried out by way of the control system Device and system failures are detected and signalled to the control system Aim of the Handbook This handbook provides essential information and advice on how to plan install and put the Remote Pro cess Interface RPI into operation In addition it provides all necessary information on status and fault indi Subject to reasona

REMOTE PROCESS INTERFACE MANUAL

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