May 2005

Safety Information in this Manual

Danger, Warning, and Caution symbols are used throughout the manual to help identify and avoid hazardous situations. Examples of each symbol are shown and explained below.

DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. It may also be used to alert against unsafe practices. (Color: red)

WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be used to alert against unsafe practices or cause product failure. (Color: orange)

Caution
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. (Color: yellow)

Table of Contents Chapter 1...............................................................................1-1

Description ...................................................................................... 1-1 Technical Specifications ............................................................... 1-2

Chapter 2...............................................................................2-1
Hardware ........................................................................................ 2-1 Mounting ....................................................................................... 2-1 Wiring............................................................................................ 2-1 Network Connector ....................................................................... 2-2 Module and Network Status LEDs ................................................ 2-3

Chapter 3...............................................................................3-1
Network Configuration..................................................................... 3-1 Local Assignment of PROFIBUS Address .................................... 3-2 Assignment of Network Data Rate ................................................ 3-4

Chapter 4...............................................................................4-1
PROFIBUS GSD File ...................................................................... 4-1 853 Three Phase Power Controller GSD File ............................... 4-2

Chapter 5...............................................................................5-1
PKW and PZD Data Capability ....................................................... 5-1 Parameter Process data Object .................................................... 5-1 Data Exchange using PPOs ......................................................... 5-3
PZD Output Data................................................................................... 5-3 PZD Input Data ..................................................................................... 5-4

Using the PKW Structure for Single Parameter Requests ............ 5-5 Error Response............................................................................. 5-7 Modifying the Assignment of PZD Data ........................................ 5-9
PZD Output Map ................................................................................... 5-9 PZD Input Map .................................................................................... 5-11

Chapter 6...............................................................................6-1
Configuration Example.................................................................... 6-1 Hardware Configuration ................................................................ 6-1 Software Configuration ................................................................. 6-4 Sample Code ................................................................................ 6-9

Chapter 7...............................................................................7-1
Troubleshooting .............................................................................. 7-1

PROFIBUS Interface LED Indicators ............................................ 7-2 Troubleshooting Guide.................................................................. 7-3

Glossary .................................................................................... i

ii

List of Figures
Figure 1-1 PROFIBUS Connectivity ............................................................................. 1-1 Figure 2-1 850 Series PROFIBUS Interface Card ........................................................ 2-1 Figure 2-2 PROFIBUS Interface Connector ................................................................. 2-2 Figure 2-3 Location of status LEDs .............................................................................. 2-3 Figure 6-1 GSD file installation..................................................................................... 6-1 Figure 6-2 Hardware configuration of test system........................................................ 6-3 Figure 6-3 FC100: Receive data from the 853 ............................................................. 6-4 Figure 6-4 FC101: Send data to the 853 ...................................................................... 6-5 Figure 6-5 S7DEMO_853 block summary.................................................................... 6-6 Figure 6-6 DB100: Input data received from the 853 ................................................... 6-7 Figure 6-7 DB100: Output data sent to the 853............................................................ 6-8 Figure 6-8 853Ctrl: Allows user to read and write variables in real time....................... 6-9 Figure 7-1 PROFIBUS Interface Board ........................................................................7-2

List of Tables
Table 1-1 Technical Specifications...............................................................................1-2 Table 1-2 Transmission Medium Specifications ........................................................... 1-3 Table 2-1 PROFIBUS Connector Pinout ...................................................................... 2-2 Table 2-2 PROFIBUS Interface Status LEDs ............................................................... 2-3 Table 5-1 PPO Data Exchange Message Format ........................................................ 5-2 Table 5-2 Master's PZD Output Data ........................................................................... 5-3 Table 5-3 853 PZD Input Data ..................................................................................... 5-4 Table 6-1 853 Output and Input Words ........................................................................ 6-2 Table 7-1 PROFIBUS Interface Status LEDs ............................................................... 7-2 Table 7-2 PROFIBUS Troubleshooting ........................................................................ 7-3

iii

Chapter 1 Description Caution

The Spang 850 Series Controller can be controlled remotely when connected to a PROFIBUS network. In order to enable the remote control, the Remote/Local digital input must be shorted.

PROFIBUS is a vendor-independent, low-level network standard that defines the connection and communication between industrial devices. PROFIBUS has two primary functions: Control of connected industrial devices Monitoring link for connected industrial devices

The Spang 850 Series PROFIBUS Interface products support the PROFIBUS-DP variant of the PROFIBUS protocol, which is a multimaster, master-slave, token passing protocol designed especially for communication between automatic control systems and distributed I/O at the device level. The open nature of the network allows equipment from different manufacturers to coexist on the same bus. The Spang 850 Series PROFIBUS Interface products are 'slave' devices; that is, they do not initiate communication. A master device on the network must establish a connection with the 850 Series PROFIBUS interface, in order for data to be exchanged. The PROFIBUS-DP network standard follows a high speed version of the RS485 standard, permitting baud rates of up to 12Mbaud. A maximum of 32 PROFIBUS-DP stations (nodes) may be contained within a single network segment. Use of RS485 repeaters allows a total of up to 127 stations.

Figure 1-1 PROFIBUS Connectivity

1-1

Description

May 2005

Technical Specifications

Table 1-1 Technical Specifications

Network Topology Medium Line Length Network Supply Voltage Network Data Rate Network Nodes Station (node) types Linear bus terminated at both ends Shielded twisted pair 1200 m max, depending on data rate 5VDC +/- 5% 9.6 Kbaud to 12Mbaud, step-wise 32 per segment, 127 with repeaters Masters (active), with bus-access control; Slaves (passive) have no bus access control 9 pin D-sub; T-type is recommended for quick network configuration Hybrid; token-passing ring between master stations; master-slave between master and slave stations NRZ bit encoding combined with RS485 signaling Half-duplex, asynchronous, no bit stuffing 250 or 150 ohm at each end of the bus, depending on cable type

Bus Connector

Bus access

Signalling

Encoding

Terminating Resistors

1-2

May 2005

Description

Table 1-2 Transmission Medium Specifications

Transmission Rate 9.6 Kbits/sec 19.2 45.45 93.75 187.5 500 1500 3000, 6000, 12000 Cable Type A Segment Length (cable type A) 1200 meters 1200 1200 1200 1000 400 200 100 Segment Length (cable type B) 1200 meters 1200 1200 1200 600 200 70

Impedance: 135 165 ohm; f = 3 20 MHz Capacity: < 30 pF/m Loop resistance: 110 ohm/km Wire diameter: 0.64 mm Core cross section: > 0.34 mm2 (22 AWG) Impedance: 100 130 ohm; f > 100 KHz Capacity: < 60 pF/m Loop resistance: na Wire diameter: 0.64 mm Core cross section: > 0.22 mm2 (24 AWG)

Cable Type B

1-3

Description

May 2005

1-4

Chapter 2 Hardware
Mounting The 850 Series PROFIBUS Interface card is mounted on the main control board inside the 850 Series Controller. The actual card mounted in the controller (850 chassis version) is shown below.

Figure 2-1 850 Series PROFIBUS Interface Card

Wiring Each station on the PROFIBUS network is connected to the medium via a 9-pin D-sub connector. The female side of the connector is located in the station (850 series Interface), while the male side is mounted on the bus cable. The bus cable (type A and type B) must be terminated at both ends by a termination resistor. The termination resistor is 220 ohms (type A cable) or 150 ohms (type B), accompanied by 390 ohm pullup and pulldown resistors. Typical PROFIBUS T connectors offer a selectable termination option. It is important to note that stations located between the terminated ends of a cable run must not be resistor-terminated.

2-1

Hardware

May 2005

Network Connector

The 850 series PROFIBUS Interface connector is a female (socket) DB9 type. The PROFIBUS cable connector is specified as a DB9 male (plug) type. Cable (plug end) connectors generally include selectable terminating resistors. Terminating resistance MUST be applied at the end stations on the network.

Figure 2-2 PROFIBUS Interface Connector

Each station on the PROFIBUS network must ensure that it provides 5 volts and GND to pins 5 and 6 of the connector. These signals are necessary for bus termination. VP (pin 5) must be capable of driving 10mA for the terminating resistors.

Table 2-1 PROFIBUS Connector Pinout

Pin number 1 RS 485 Reference Signal SHIELD
(2)

Description Shield, protective ground -24V output voltage Receive/Transmit Data N Control P Data ground Voltage - plus
(2)

2 3 B/B'

- 24 V

(2)

RxD/TxD - P
(2)

4 5 6 7 8 A/A' C/C'

CNTR P DGND VP
(1)

+ 24 V

+24V output voltage Receive/Transmit Data - N Control N

RxD/TxD - N
(2)

CNTR N

(1) Signal is only necessary at the end node (station at the end of the bus) (2) These signals are optional.

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May 2005

Hardware

Module and Network Status LEDs

Figure 2-3 Location of status LEDs

The interface card uses three LEDs to describe Module and Network status. The LEDs flash during power up as a self-test. Status is summarized in the following table.

Table 2-2 PROFIBUS Interface Status LEDs

LED D6 (green), D3 (green), D5 (red) D5 State Off Description There is no power applied

On

Interface board is not communicating with control board No network activity Configuration incomplete Interface is configured and exchanging data with its master

D5, D3 D3 D6, D3

Flashing Flashing On

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Hardware

May 2005

2-4

Chapter 3 Network Configuration

DANGER
Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, operate, and/or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

Caution
The 850 Series Controller is configured using the programmable settings. Programming the settings incorrectly can cause the controller to exhibit intermittent or full output conditions.

In order to communicate across PROFIBUS, the 850 Series controller must be configured as a node (station) on the PROFIBUS network. Each station on the network must have a unique address in the range 0 - 126. The default slave address is 126; however, address 126 is NOT a valid slave address for IO data exchange. There are two methods available for setting the address of the 850 Series controller: 1) by a master station over the network (refer to the Communication chapter); or 2) locally, using the Configuration Tool supplied with the 850 Series controller. In either case, it is imperative that the station address remain unique on the network throughout the configuration process.

3-1

Network Configuration

May 2005

Local Assignment of PROFIBUS Address Note: The 850 Series Controller must be under Local control (i.e, the Remote/Local input is open) to enable write capability from the Configuration Tool. Refer to the specific 850 Series product manual (SPE-AM 851, SPE-AM 853, etc) for detailed information on the Configuration Tool. Establish on-line communication between the 850 Series Controller and the accompanying Configuration Tool. Open the settings window, and select the Network Tab. Set the Network Type for PROFIBUS.

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May 2005

Network Configuration

Set the Network Address. It is the user's responsibility to assign a station address which is UNIQUE on the network. There is no address arbitration procedure on the PROFIBUS network; duplicate station addresses will result in undefined network behavior.

3-3

Network Configuration Set the Network Loss Option for desired operation.

May 2005

This setting defines 850 Controller behavior in the event that communication over the network is lost. FAULT and STOP IGNORE and RUN The 850 Controller will indicate a fault and the output will be shut off. There is no indication of network loss, and the 850 Controller continues normal operation. The 850 Controller will indicate an alarm and continue normal operation.

ALARM and RUN

Assignment of Network Data Rate The 850 series PROFIBUS interface is an AUTOBAUD device. When the interface is added to the PROFIBUS network, it senses the network baud rate, and sets its own baud rate accordingly.

3-4

Chapter 4 PROFIBUS GSD File

The PROFIBUS specification requires that an electronic device description accompany each PROFIBUS interface product. The electronic data sheet is an ASCII text file referred to as a 'GSD' file. The GSD file contains information about the product manufacturer, communication rates and timing, product options, and device parameters. Availability of GSD files enables the user to configure a PROFIBUS network using any of several vendor-independent, network configuration tools. The GSD file (SPE0773e.gsd) of the 853 Three Phase Power Controller follows the format defined by PROFIBUS International. The filename corresponds to the product 'Ident Number' assigned by PROFIBUS International.

4-1

PROFIBUS GSD

May 2005

853 Three Phase Power Controller GSD File

; Device Data File for 853 Three Phase Power Controller ; Copyright (c) 2004, Spang Power Electronics ; GSD Rev 3.0 #PROFIBUS_DP GSD_Revision = 2 Vendor_Name = "Spang Power Electronics" Model_Name = "853 Three Phase Power Control" Revision = "Rev 8.x" Ident_Number = 0x0773 Protocol_Ident = 0 Station_Type = 0 FMS_Supp = 0 Hardware_Release = "Rev B" Software_Release = "8.00x" ; Supported baudrates 9.6_supp = 1 19.2_supp = 1 93.75_supp = 1 187.5_supp = 1 500_supp = 1 1.5M_supp = 1 3M_supp = 1 6M_supp = 1 12M_supp = 1 ; Maximum responder time for supported baud rates MaxTsdr_9.6 = 60 MaxTsdr_19.2 = 60 MaxTsdr_93.75 = 60 MaxTsdr_187.5 = 60 MaxTsdr_500 = 100 MaxTsdr_1.5M = 100 MaxTsdr_3M = 200 MaxTsdr_6M = 200 MaxTsdr_12M = 200 ; Supported hardware features Redundancy = 0 Repeater_Ctrl_Sig = 2 24V_Pins = 0 ; Slave Specific Freeze_Mode_Supp = 0 Sync_Mode_Supp = 0 Auto_Baud_Supp = 1

The 853 is an 'autobaud' device; it supports all of the baudrates defined for Profibus networks.

'Max_Tsdr' is the maximum time allowed to pass before the slave responds to the master. It is specified in 'Tbits', a time equal to the inverse of the baud rate. One Tbit at 12M = 83nsec

The 853 will configure itself to the existing network baud rate upon powerup. The network address of the 853 is set by the master through SAP 55.

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May 2005

PROFIBUS GSD

Set_Slave_Add_Supp = 1 ; Maximum length of user parameter data User_Prm_Data_Len = 0 ; Default user parameter string ; none Slave_Family = 0@Spang Min_Slave_Intervall = 2 Modular_Station = 1 Max_Module = 3 Max_Input_Len = 32 Max_Output_Len = 32 Max_Data_Len = 56 Max_Diag_Data_len = 8 Each 'Module' mirrors a PPO type defined for the 850 series. Module 1 corresponds to PPO 1, Module 2 is the same as PPO 2, and so on. Modules 1 and 2 define the output and input data lengths, and include the 850 setting numbers assigned to the output and input data. Module 3 defines the output and input data lengths, but does not include setting numbers; the assignment (configuration) stored in the 850 will be used.

Module = "5WOut 10WIn - config follows" 0xCD, 0xC4, 0xC9, 68, 17, 54, 75, 72, 30, 63, 74, 119, 11, 50, 13, 65 ; 5w out, 10w in, data follows 1 EndModule Module = "PKW + 5Out 10In - config follows" 0xCD, 0xC8, 0xCD, 68, 17, 54, 75, 72, 30, 63, 74, 119, 11, 50, 13, 65 ; PKW + PZD, 5w out, 10w in, data follows 2 EndModule Module = "PKW + 5Out 10In - config saved" 0xC0, 0xC8, 0xCD ; PKW + PZD, 5w out, 10w in, no data follows 3 EndModule ; Spang 853 Configuration specific parameters ; Spang_Icon_File = "SP850.ico"

4-3

PROFIBUS GSD

May 2005

4-4

Chapter 5 PKW and PZD Data Capability

The 850 series power control products utilize a PROFIBUS communication structure similar to that defined in the PROFIDRIVE profile published by the PNO (PROFIBUS User Organization). The PROFIDRIVE profile describes the structure of the cyclic data telegram as a combination of parameter data and process data. The structure is referred to as a PPO (Parameter Process data Object) type. Parameter Process data Object The Parameter Process data Object (PPO) consists of a parameter segment (PKW) and a process data segment (PZD). The PKW segment is used to transfer a single parameter request from the master to the slave, and for the slave to provide a response to the masters request. The request is handled as acyclic communication. The slave response to the PKW request may not be ready in the immediate response telegram. The PZD segment is the cyclic portion of the telegram. The slaves cyclic response information will always be present in the PZD segment of its response. The following table describes the PPO types available for 850 series communication. They are defined as modules in the 850 series gsd file. The desired configuration is assigned by the master in the configuration telegram. Note that not all PPO types contain a PKW message segment. If purely cyclic communication is desired, the 850 series product can be configured as such.

5-1

Parameter Process data Object (PPO)

May 2005

Table 5-1 PPO Data Exchange Message Format

PKW

PZD

PKE

IND

PWE

PZD1

PZD2

PZD3

PZDn

Type 1: Octet String (20 max)

5 words out, 10 words in

Type 2: Octet String (28 max)

PZD1 CTW STW

PZD2

PZD3

PZDn

PKW: PZD: PKE: IND: PWE: CTW: STW:

Parameter ID / Value Process Data; cyclically transmitted Parameter ID (octets 1-2) Sub-index (octets 3-4) Parameter Value (octets 5-8) Control Word (request) Status Word (response)

5-2

May 2005

Parameter Process data Object (PPO)

Type 1 communication does not include a PKW segment. Type 1 is defined as 5 words of PZD (process) data out (from the master), and 10 words of PZD data in (to the master). Type 2 communication includes the 8-byte PKW (parameter) segment, 5 words of process data out, and 10 words of process data in. The default PPO type for the 853 is PPO 1, described as 5 words of output data (control information from the master), and 10 words of input data (status information sent to the master). There is no PKW segment in the 853 default configuration. Data Exchange using PPOs The slave's diagnostic response indicates satisfactory configuration, and whether or not it has a master (4th byte of diagnostic response). When the master detects the satisfactory configuration of its slave (by repeated requests for diagnostics), the master and slave enter the Data Exchange mode. The Data Exchange mode is marked by the transfer of process data between the master and slave in a queryresponse, or polled, arrangement. The master sends output data to the slave and receives input data in response. The master's output data is written to the 853. Input data is data read from the controller and sent to the master. If the slave has been configured for data transfer involving PKW (parameter) data, the PKW portion of the message will be handled apart from the PZD (process) data. PZD Output Data The PZD output data (from master to 853 slave) is summarized below. The first two bytes of PZD output data are ALWAYS the Control Word (setting 93). No other 853 setting may be mapped to this output.

Table 5-2 Master's PZD Output Data

PZD Byte 0,1 2,3 4,5 6,7 8,9 Contents Output 1 data Output 2 data Output 3 data Output 4 data Output 5 data Default Mapping Setting 93 Control Word (ALWAYS) Setting 68 Power Output Setpoint Setting 17 Voltage Output Setpoint Setting 54 Current Output Setpoint Setting 75 Duty Cycle Setpoint

5-3

Parameter Process data Object (PPO)

May 2005

PZD Input Data The PZD input data (from 853 Controller to master) is summarized in the following table. The first two bytes of the PZD input data are ALWAYS the Status Word (setting 94). No other 853 setting may be mapped to this input. Input data is READ-ONLY and cannot be altered by the master.

Table 5-3 853 PZD Input Data

PZD Byte 0,1 2,3 4,5 6,7 8,9 10,11 12,13 14,15 16,17 18,19 Contents Input 1 data Input 2 data Input 3 data Input 4 data Input 5 data Input 6 data Input 7 data Input 8 data Input 9 data Input 10 data Default Mapping Setting 94 Status Word (ALWAYS) Setting 72 Power Output Setting 30 Voltage Output Setting 63 Current Output Setting 74 Duty Cycle Out Setting 119 Fault Code Setting 11 Voltage In Setting 50 Current In Setting 13 Frequency (actual) Setting 65 KVA In

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May 2005

Parameter Process data Object (PPO)

Using the PKW Structure for Single Parameter Requests The PKW is an 8 byte segment at the front of the data exchange message. The PKW is used by the master to issue a single parameter request. The slave processes the request and formulates the response to it. It is important to note that the slaves PKW response may not be ready to be included in the immediate cyclic response telegram. The slave will include its PKW response in a subsequent cyclic response after it has processed the request. The slave is unable to respond to a new parameter request until the current request has been completed. It is the responsibility of the master to maintain the order and timing of parameter requests within the cyclic message. The 8-byte PKW segment is interpreted as follows:
PKW PZD

PKE

IND

PWE

PZD1

PZD2

PZD3

PZDn

PKE: IND: PWE:

Parameter ID (octets 1-2) Sub-index (octets 3-4) Parameter Value (octets 5-8)

The PKE (Parameter ID) is a 16 bit value which contains the request/response code and parameter number. Bits 0 10 identify the 853 parameter number. Bit 11 is unused. Bits 12 15 identify the request/response.
Parameter ID (PKE) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Identifier (ID) REQUEST 0 = no request 1 = read 2 = write RESPONSE 0 = no response 1 = transfer resp 7 = error resp 8 = no master

Parameter Number (PNU)

PNU numbers 1 119 correspond to 850 series settings PNU numbers 150 164 correspond to process data settings

The IND (index) is currently reserved for future use. The PWE is a 16 bit value transferred high byte first. For a parameter read request, the PWE contents are undefined. Likewise in a parameter write response, the PWE contents are undefined.

5-5

Parameter Process data Object (PPO) As an example, the PKW read request of 853 setting number 95 (Ramp Up Time) is as follows:
PKW PZD

May 2005

PKE 10 5FH PKE: IND: PWE:

IND 00 00

PWE 00 00 00 00

PZD1

PZD2

PZD3

PZDn

Read request, Parameter number 95 Not used Not used for Parameter Read

The PKE is determined as follows:

Parameter ID (PKE) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Identifier (ID) 1 = read request 0 0 0 1 0 0 0 0

Parameter Number (PNU) 95 (x5F) = Ramp Up Time 0 1 0 1 1 1 1 1

The master continues to issue the same PKW request in the cyclic message exchange until a PKW response is received. Only one PKW task is processed at any one time. The slave will issue a no response in the PKW segment of its cyclic response until the PKW request has been processed.
PKW PZD

PKE 00 5FH PKE: IND: PWE:

IND 00 00

PWE 00 00 00 00

PZD1

PZD2

PZD3

PZDn

No response, setting number 95 Not used Not used for No response

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May 2005

Parameter Process data Object (PPO)

When the slave has processed the PKW request, it will issue a transfer response or an error response.
PKW PZD

PKE 10 5FH PKE: IND: PWE:

IND 00 00

PWE 00 00 00 0AH

PZD1

PZD2

PZD3

PZDn

Transfer response, setting number 95 Not used Current value of setting number 95 (eg, 10 seconds)

The slave continues to provide the last response PKW until the master formulates a new request. A PKW read response always provides the current value. Error Response If the slave cannot process the PKW request, it issues an error response. If the error identifier in the slave response is 8, it means the master does not have control of the slave for PKW processing. The slaves configuration is probably incorrect. If the error identifier in the slave response is 7, the error is described in the PNU field.

Parameter ID (PKE) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Error Identifier

Error Codes

7 = error resp 8 = no master

0 = illegal parameter number 1 = Parameter value cannot be changed 17 = request cannot be processed due to operating state 18 = unspecified error

5-7

Parameter Process data Object (PPO)

May 2005

As an example, a request to write a new value to a read-only setting, such as status, will return an error. Request:
PKW PZD

PKE 20 5EH PKE: IND: PWE:

IND 00 00

PWE 00 00 AA 55H

PZD1

PZD2

PZD3

PZDn

Write request, setting number 94 (Status) Not used Desired value of setting number 94

Response:
PKW PZD

PKE 70 5EH PKE: IND: PWE:

IND 00 00

PWE 00 00 00 11H

PZD1

PZD2

PZD3

PZDn

Error response, setting number 94 (Status) Not used Error 17, request cannot be processed due to operating state

Important Note The PKW message segment cannot be used to modify an 853 setting that is mapped to a PZD output. As an example, the control word (setting 93) is mapped to PZD output one. This means that a PKW request to write the control word will generate an error response.

5-8

May 2005

Parameter Process data Object (PPO)

Modifying the Assignment of PZD Data The data telegram is used for the cyclic transfer of data between master and slave. PPO capability breaks the data telegram into an acyclic PKW (parameter) segment and a cyclic PZD (process) segment. The process data are applied to settings assigned by the information sent from the master to the slave during configuration. It is possible to modify the settings referenced in the data telegram by using the PKW segment of the data telegram. Note that the first output word must always remain the control word, and the first input word will always be the status word. The PZD data is defined as 16 bit values transferred as bytes, high byte first. Each word of data corresponds to an 853 setting. Output data is written to the setting; input data is read from the setting. The list of settings addressed in the PZD data is an array that can be accessed as parameter numbers 150 164. The mapping of PZD position to parameter is illustrated below. PZD Output Map
PZD Offset 0 2 4 6 8 Parameter Number 150 151 152 153 154 Description / Default Mapping Output 1 data / Setting 93 Control Word (ALWAYS) Output 2 data / Setting 68 Power Setpoint Output 3 data / Setting 17 Voltage Setpoint Output 4 data / Setting 54 Current Setpoint Output 5 data / Setting 75 Duty Cycle Setpoint

Any 853 setting that can be modified is a valid output parameter. For example, to change Output 2 from setting 68 (Power Setpoint) to setting 17 (Voltage Setpoint) the PKW message segment would look like the following:

5-9

Parameter Process data Object (PPO) PKW Request:

PKW PZD

May 2005

PKE 20 97H PKE: IND: PWE:

IND 00 00

PWE 00 00 00 11H

PZD1

PZD2

PZD3

PZDn

Write request, Parameter number 151d = 97H Not used New 853 setting number 17d = 11H

Changes to the PZD output map should be made with the 850 unit output OFF. It is the users responsibility to ensure proper values are set in the PZD output data before turning the unit output on. The PKW response:
PKW PZD

PKE 10 97H PKE: IND: PWE:

IND 00 00

PWE 00 00 00 00

PZD1

PZD2

PZD3

PZDn

Transfer response, Parameter number 151d = 97H Not used Not used

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May 2005

Parameter Process data Object (PPO)

PZD Input Map

PZD Offset 0 2 4 6 8 10 12 14 16 18 Parameter Number 156 157 158 159 160 161 162 163 164 165 Description / Default Mapping Input 1 data / Setting 94 Status Word (ALWAYS) Input 2 data / Setting 72 Power Output Input 3 data / Setting 30 Voltage Output Input 4 data / Setting 63 Current Output Input 5 data / Setting 74 Duty Cycle Out Input 6 data / Setting 119 Fault Code Input 7 data / Setting 11 Voltage In Input 8 data / Setting 50 Current In Input 9 data / Setting 13 Frequency (actual) Input 10 data / Setting 65 KVA In

Any 853 setting is a valid input parameter. To change Input 6 from setting 119 (Fault Code) to setting 102 (Product Code) the PKW message segment would look like the following:
PKW PZD

PKE 20 A1H PKE: IND: PWE:

IND 00 00

PWE 00 00 00 66H

PZD1

PZD2

PZD3

PZDn

Write request, Parameter number 161d = A1H Not used New 853 setting number 102d = 66H

The PKW response:

PKW PZD

PKE 10 A1H PKE: IND: PWE:

IND 00 00

PWE 00 00 00 00

PZD1

PZD2

PZD3

PZDn

Transfer response, Parameter number 161 Not used Not used

5-11

Chapter 6 Configuration Example

This chapter describes the setup and operation of an 853 Three Phase Power Controller as a slave device on a PROFIBUS network. The Siemens S7 400 PLC is the master. The Simatic Step 7 v5.2 configuration software was used in this example. Hardware Configuration The hardware configuration consists of a nine-slot rack; Siemens power supply PS407 4A; main processor CPU 412-5; extended communication processor CP 443-5; and a Spang Power Electronics 853 Three Phase Power Controller. In the Step 7 project, add the Siemens hardware and install the 853. To install the 853 into the Step 7 device database, add its GSD file. From the Step 7 hardware configuration window, select Options > Install new GSD. Browse for the 853 GSD file, labeled SPE_0773.gsd, and add it to the device library. After the GSD file has been added to the device database, the 853 will appear in the device list under Additional Field Devices > General > Spang. Double click the device to add it to the HW configuration.

Figure 6-1 GSD file installation

6-1

Configuration Example

May 2005

Several input/output modules are defined in the 853 GSD. This example uses module 1, 5 Words Out, 10 Words In config follows, defined as 5 words of output data and 10 words of input data. The module describes the information passed between the S7 400 PLC master and the 853 slave in Data Exchange mode. The information is described below.

Table 6-1 853 Output and Input Words

Output Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Word 8 Word 9 Word 10 Control Word (93) Power Output Setpoint (68) Voltage Output Setpoint (17) Current Output Setpoint (54) Duty Cycle Setpoint (75) Status Word (94) Power Output (72) Voltage Output (30) Current Output (63) Duty Cycle Output (74) Fault Code (119) Voltage Input (11) Current Input (50) Frequency (13) KVA In (65) Input

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Configuration Example

The hardware configuration is shown below.

Figure 6-2 Hardware configuration of test system

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Configuration Example

May 2005

Software Configuration Transfer instructions in the Siemens S7 400 PLC are limited to a max of 4 bytes of consistent data. Since the data between the PLC and the 853 has a maximum of 14 words, two System Function calls are used to read and write data. The System Function calls are SFC14 (read consistent data of DP standard slave), and SFC15 (write consistent data to a DP standard slave). The use of system function calls ensures the consistency of data over the length of the data exchange. The S7 demo project has two User Function Calls which utilize SFC14 and SFC15, and are illustrated in the following figures.

Figure 6-3 FC100: Receive data from the 853

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Configuration Example

Figure 6-4 FC101: Send data to the 853

The SFC14 and SFC15 connect to the PROFIBUS DP standard slave by the word assigned to the LADDR input. The word must be the same as defined in the hardware configuration of the selected I/O module, which was I address (512D or 200H) and Q address (512D or 200H). The user function calls, FC100 and FC101, are in the main program block (OB1) of the Siemens S7 400 PLC. Additional organizational blocks are needed to handle error and fault conditions. A list of the organizational blocks used in the S7DEMO_853 program is shown on the following page.

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Figure 6-5 S7DEMO_853 block summary

Data is transferred from the system function calls to a custom data block DB100. The data block maps the data to memory by assigning tags matching the definition of the selected I/O module. The data block must be the exact length of the configured data exchange. Control word bits and status bits are assigned individually, and are easy to see/access. Note that the word storage in the Siemens S7-400 PLC has the high and low bytes switched. The data block accommodates this structure. The data block definition is illustrated in the following figures.

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Configuration Example

Figure 6-6 DB100: Input data received from the 853

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Configuration Example

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Figure 6-7 DB100: Output data sent to the 853

The variable table 853Ctrl was created to use for testing. The variable table is accessible online and allows the user to change variables while the Siemens S7-400 PLC is running. The definition of the variable table is shown below.

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Configuration Example

Figure 6-8 853Ctrl: Allows user to read and write variables in real time.
Sample Code The sample code using SIMATIC Step 7 v5.2 software has been tested and is available by request.

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Chapter 7 Troubleshooting

DANGER
Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, operate, and/or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

DANGER
The user is responsible for conforming with all applicable local, national, and international codes; wiring practices, grounding, disconnects, and overcurrent protection are of particular importance. Failure to observe this precaution could result in severe bodily injury or loss of life.

DANGER
This equipment is at line voltage when AC power is connected. Disconnect and lock out all ungrounded conductors of the AC power line. Failure to observe these precautions could result in severe bodily injury or loss of life.

DANGER
Power must be applied to the 850 Series Controller with the cover removed to perform certain troubleshooting procedures. Voltages on many components are at incoming line potential. To avoid electric shock hazard or damage to equipment, do not touch any component other than those specified in the manual. Failure to observe these precautions could result in severe injury or loss of life.

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May 2005

PROFIBUS Interface LED Indicators The following figure illustrates the location of module and network status LEDs on the PROFIBUS interface card.

Figure 7-1 PROFIBUS Interface Board

The interface card uses three LEDs to describe Module and Network status. The LEDs flash during power up as a self-test.

Table 7-1 PROFIBUS Interface Status LEDs

LED D6 (green), D3 (green), D5 (red) D5 State Off Description There is no power applied

On

Interface board is not communicating with control board No network activity Configuration incomplete Interface is configured and exchanging data with its master

D5, D3 D3 D6, D3

Flashing Flashing On

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Troubleshooting

Troubleshooting Guide

Table 7-2 PROFIBUS Troubleshooting

Condition Control Board Heartbeat LED off Possible Cause DSP on main control PCB failed Corrective Action Check for control power Check that jumper JP1 is removed before applying power Replace main control PCB PROFIBUS Status LEDs off No Control Power Insure the 850 Series Controller has separate control power Check Power Supply connections to main control PCB Check connection between the PROFIBUS Interface PCB and the main control PCB. Replace Power Supply Verify PROFIBUS Interface flashes LEDs on power up Verify Heartbeat LED on main PCB Replace main control PCB D5 (red), D3 (green) flashing The PROFIBUS Interface detects no network activity Verify PROFIBUS Interface flashes LEDs on power up Verify presence and operation of PROFIBUS network Replace PROFIBUS Interface PCB D3 (green) flashing Configuration incomplete Check Network Address setting (use 850 Series Configuration Tool or PROFIBUS configuration tool) Use PROFIBUS configuration tool to check master's configuration data

Power Supply connection open Interface PCB connection open

Power Supply failed D5 (red) LED on The PROFIBUS Interface is not communicating with the main control board

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Troubleshooting

May 2005

7-4

Glossary
Glossary of common terms and abbreviations used in SCR Power Controllers and their applications

Term or Acronym
ASCII Autobaud GSD I/O LED NC NO NEC NEMA PCB PCMCIA PKW PLC PPO PROFIBUS PROFIBUS-DP

Description
American Standard Code for Information Interchange The ability of a device on a network to sense the network baud rate PROFIBUS Electronic Device Description Input/Output Light emitting diode Normally closed contact Normally open contact National Electric Code National Electrical Manufacturers Association Printed Circuit Board Personal Computer Memory Card International Association Parameter segment of a PPO-style cyclic PROFIBUS message Programmable Logic Controller Parameter Process data Object A vendor-independent, low-level, industrial network standard A master-slave, token-passing protocol designed specifically for automated control and device-level IO. A variant of the PROFIBUS protocol. Process-data segment of a PPO-style cyclic PROFIBUS message Root Mean Squared Receive Silicon Controlled Rectifier Reference for PID control Transmit

PZD RMS Rx SCR Setpoint Tx

Glossary

May 2005

Term or Acronym
VAC VDC VRMS

Description
Volts Alternating Current Volts Direct Current Volts Root Mean Squared

ii