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Profibus control actuator

Process Field Bus

Profibus
Serial communication and control of Rotork actuators

Publication S113E Date of issue 12/04

Profibus Actuator Control

Profibus-DP serial communication is ideally suited to the control of Rotork actuators. A network using ProfibusDP provides a cost effective method for connecting actuators in any location to the central control system simply and efficiently. The Profibus-DP network can operate over a range of communication speeds and provides the mechanism for control of the actuator and feedback of data about the valve. The latest Rotork Profibus-DP option cards support standard DP-V0 cyclic data exchange and DP-V1 acyclic data exchange used for diagnosis, set-up and historical data. The provision of EDD files allows the latest Siemens PDM utilities to be used during configuration whilst the DTM file allows the new non-proprietary FDT utility to be used. The standard GSD files allow all complexities of the system, including basic, to be set up.

Rotork Profibus DP-V1 module

International Open Standard IEC 61158/EN5170 Suitable for RS485 Profibus DP bus DP-V0 cyclic and Dp-V1 acyclic data compliant Highly reliable standardised communications Compatible with Rotork IQ, IQT and Q range electric actuators Low installation and maintenance costs, high control system flexibility Data transfer between 9600 baud and 1.5 Mbaud Support for Simple Dual Channel Redundancy Support for RedCom redundancy to PNO specification 2.212 Support for Process Device Manager (PDM) and Field Device Tool (FDT) utilities GSD, EDD and DTM device description files available Three versions of the device: Single Channel with additional Analogue input, Simple Dual Channel and Dual Channel with RedCom compliance.

For more information on Profibus consult the website at http://www.Profibus.com. Profibus is supported by leading PLC manufacturers such as Siemens and Mitsubishi

Rotork Profibus DP-V1 Module

The Profibus module is fitted inside the actuator electrical housing and interfaces directly with the actuator electronics. Once fitted, all the normal commands associated with moving the actuator together with feedback and some historical data become available on the Profibus DP, RS485 highway. There are a number of user settings to be made for the system variables and actuator performance, such as the slave address of the actuator. These are set by either using the infra-red communicator link to the IQ and IQT actuator or by parameterising over the network to the appropriate registers in the module using a suitable tool. The GSD file can be edited in a simple text editor to modify the internal parameters during Profibus start-up. All the settings are held in non-volatile EEPROM memory on the card

Dual Channel Profibus Module

Profibus DP Communication Highway

PLC Address 1 Address 2 Address 3

1200 metres at 9600 baud

The Profibus DP module is a slave device supporting normal cyclic communication with the PLC using V0 communication and also supporting acyclic communication using V1 communication.

The Profibus highway uses RS485, 2 wire communication. Up to 126 devices can be connected on a single network provided suitable repeaters are included. Without repeaters only 32 devices, including the PLC, are allowed. Address 126 is reserved for a new device appearing on the highway.

Data Rate (Baud) Maximum Segment Length Maximum Highway Length Max No. of actuators/segment

9600 1.2km 10km 31

19200 1.2km 10km 31

93.75k 1.2km 10km 31

187.5k 1000m 10km 31

500k 400m 4km 31

1.5M 200m 2km 31

Note: Each actuator internal wiring is arranged so that the stub length is zero. Calculations are based on Type A Profibus cable

Profibus Single Channel Module

The single channel option is the simplest implementation of the Profibus Module. The actuator is connected to one highway only and an additional input for an instrument analogue transmitter signal (current or voltage) is provided. Two pairs of data highway terminals are provided to ensure zero stub length inside the actuator. Single highway systems provide the maximum cost benefit to the installer. There is only one cable, and the hardware costs and installation costs are minimised, in addition the engineering involved with a single channel system is simpler.

Profibus Dual Channel Modules

Simple Dual Channel Module
The simple dual channel version caters for those applications where redundant highways are being used and the host PLC does not support a full RedCom system. The two channels are isolated from one another and provide redundant communication paths without including the special functions required by RedCom. This module is the ideal choice for redundant control when the PLCs do not have the capability to support full RedCom facilities. Although two highways are used there is only a marginal additional cost for the increased availability of the plant. There is a small increase in the field hardware and installation costs which is often acceptable when viewing the overall plant requirements.

RedCom Dual Channel Module

For those systems able to support the latest Profibus standards the RedCom Dual Channel Module is fully compliant with 2.212. Profibus RedCom slave redundancy allows a single actuator to support two methods of dual communications with a host PLC. The Profibus module is able to support DP-V0 cyclic communication, DP-V1 acyclic communication and also the extensions to the V1 protocol that allow RedCom to be implemented. The Profibus module has two Profibus interface chips that allow for one or two communication channels and redundancy either by two highways (SR System Redundancy) or a single highway (FR Flying Redundancy). Where redundancy of the communications network is required SR should be used, whilst if redundant communication to a single device is the prime requirement, FR can be used. SR and FR redundancy modes supported Fully supports extensions to Profibus protocol for RedCom support Primary and Backup slaves inside the Profibus module exchange parameterisation data In FR mode the backup slave address is offset by 64

P Pr ro of fi ib bu us s M Mo od du ul le e O Op pt ti io on ns s r L2 +

Redundant Communications Simple and RedCom Operation

The two versions of the Profibus module that cater for redundant communication ensure that both simple dual PLC and fully integrated redundant PLC configurations can take advantage of system and flying redundancy. RedCom compliant PLCs and systems require extended diagnostic messages that can be a nuisance to ordinary simple PLCs. The Profibus Dual Channel module switches modes between simple and fully RedCom compliant applications simply by changing a parameter set by the GSD file. Both versions will automatically switch Primary to Backup and Backup to Primary when searching for communication. This switching will occur whenever communications on the primary channel is lost. Communication always takes place with a channel in Primary mode. RedCom is only suitable for use with compliant PLC systems.

Fig 1: RedCom Profibus Redundancy System

Device Description Files

The Rotork Profibus module is provided complete with Device Description files for 3 methods of configuration. The standard GSD files supported by all Profibus Class 1 masters and MS0 cyclic communication services are augmented by the EDD files used by PDM and by DTM files as used by FDT utilities.

FDT Field Device Tool

FDT (Field Device Tool) technology standardises the communication interface between field devices and systems. The utility allows off line or on line configuration of a Profibus network and preparation of download files for Profibus devices. In order to create the specific application each device on the network is required to have a device description file called a DTM Device Type Manager. The Rotork Profibus Module DTM allows all the settings for the Profibus card to be made and torque profiles and settings to be viewed.

PDM Process Device Manager

PDM is a Siemens utility which is very similar to FDT and allows the Profibus network to be configured on or off line. The individual Profibus devices each require a special Electronic Device Description (EDD) file to be used by the utility. The Electronic Device Description Language (EDDL) conforms to the CENELEC Standard EN50391 and EDD is a standard for PROFIBUS. The Rotork Profibus Module EDD allows all the settings for the card to be made and also allows control and monitoring. In addition torque profiles and settings can be viewed.

GSD Standard Device Description Tool

The GSD data file allows for parameterisation of the Profibus module from any host PLC using cyclic V0 communication. This includes the selection of the Module Configuration parameter that selects the data registers to exchange in cyclic mode. Three GSD files are available, one for the each of the three module types.

GSD

Profibus Control Features

Feedback and Control
The Profibus module cyclic data collected from the actuator gives information about the status of the valve and actuator combination. In addition full digital and analogue control of the actuator is available without the need to add more components. Acyclic data that may be collected by MS1 messaging includes logged data when the module is in an IQ or IQT actuator. The actual data exchanged during cyclic messages (MS0 messaging) is selected during configuration by choosing the modules to be exchanged.

Feedback Data
Digital Inputs: IDATA1 Actuator moving Close limit switch Open limit switch Actuator running closed Actuator running open Remote control selected Local stop selected Local control selected IDATA2 Thermostat tripped Monitor relay Valve obstructed Valve jammed Manual movement Moving inhibited Positioner moving actuator Watchdog recovery IDATA3 Battery low Open interlock input Close interlock input Aux input 1 Aux input 2 Aux input 3 Aux input 4 Slow mode IDATA4 GSD configuration permitted Reserved Control contention Partial stroke in progress Part stroke error Primary (0) of Backup (1) 1 or 2 channels available SR (0) or FR (1) nodes Analogue Inputs: Measured actuator position User analogue input channel Current actuator torque value

IQ
                                  

IQT
                                  

Q
                                  

Control Data
Digital Outputs: ACTCON Stop Close Open ESD Positioner enable Part stroke O_STAT Relay 1* Relay 2* Relay 3* Relay 4* Analogue Outputs: Desired actuator position

IQ
          

IQT
          

Q
          

Note: The Aux input 1-4 and Relay 1-4 outputs may be used for direct actuator remote control and indication. * Remote input and relay board must be fitted

Valve Torque Profile Data

Profibus DP-V1 messaging allows for the transfer of background data between the actuator and the host PLC or a PC on the network. V1 messages are in addition to the V0 cyclic messages used for control and monitoring.
Starts - Open Starts - Close 7346 7782

Closed 0 10 20 30 40 50 60 70 80 90 100 Open

Opening Direction Torque

The Profibus module records the torque profile of the IQ and IQT actuators in both the opening and closing directions in 22 registers that can be examined by a host system with V1 capability. In addition a further 4 registers give the number of motor starts in each direction and further registers give information on the actuator torque settings. An OPC server or similarly equipped PLC, PDM or FDT ca be used to view this data.
6

Closed 0 10 20 30 40 50 60 70 80 90 100 Open

Closing Direction Torque

Parameterisation
When a Profibus slave connects to a host the GSD file values are used to set various parameters in the slave. For the Rotork Profibus module these parameters include the basis actuator performance settings for network control as listed in the table. These parameters may also be set by a master using EDD or DTM files and in these cases there are many more settings available including the ability to inhibit the GSD file values from altering the settings made by the PDM or FDT utility. Full details of the capabilities of these files is shown in the instruction manuals for the cards.

Description
Limited Range Position Min & Max Deadband and Hystersis Motion Inhibit Time Manual Movement Travel Valve Jammed Time Watchdog Timeout & Comms Fault Timer Action on Loss of Comms Loss of signal position Aux Input Mask & ESD DI-4/Net Disable Redundancy FR/SR mode Actuator type

Configuration
The configuration of the Profibus module may be selected during the start up routine for the module when it connects to the highway. Profibus allows for a configuration telegram to be sent to the device to select the arrangement of the data that will subsequently be exchanged during the normal cyclic communication. The Rotork Profibus module has 10 possible configurations that allow varying amounts of data to be exchanged. The choices permit the user to optimise the communication so that data not required by the PLC is not collected. The default setting of Configuration 1 collects all the data from an IQ or IQT actuator.

Config
ACTCON POS_DV O_STAT PORTCM IDATA1 IDATA2 IDATA3 IDATA4 TORQUE POSITION ANALOG

1
         

2


3
 

4


5
 

6
 

7
     

8
        

9 10
             

   

     

   

      

     

Lightning Protection
The Profibus RS485 communication ports are fitted with gas discharge tubes to reduce the effect of high voltage transients on the network cables. One discharge tube is provided per port. The protection can be enhanced by the addition of external lightning arrestors. The inclusion of extra components may reduce the operating speed for the network. A varistor is included on the screen connection, which is isolated from earth, as a discharge path for high voltages induced on the cable screen.

Profibus Technical Data

Dual Channel Profibus Module

Interface: Number of channels:

EIA-485 (RS-485) suitable for 2 wire connection 1 on Single channel, fully isolated from actuator circuits 2 on Simple and RedCom Dual channel, fully mutually isolated 0 to 126, default address 126 9600 baud to 1.5 Mbaud Profibus DP, compliant with IEC61158 and EN50170 Cyclic DP-V0, Acyclic DP-V1 and Redcom protocol extensions PNO certified for Profibus standard compliance EDD (for PDM), DTM (for FDT) and GSD files plus DIB icon file 1 on Single channel, 4-20mA or 0-5V dc, externally powered, 0.1% resolution and 1% linearity at 20C, fully isolated 4 off (IQ and IQT only), potential free input contacts 4 off contacts 5A, 120V AC or 30V, 30W DC (IQ and IQT only, requires additional relay board option) Suitable for fitting within Rotork IQ, IQT and Q range actuators -40 to +70C, environmentally protected by Rotork actuator double sealing to IP68 All Profibus module power is taken from the actuator, no external supply is required

Address range: Data rate: Communication Protocol: Data Communication: Certification: Device Description Files: Analogue Input: User defined Digital Inputs: User defined Digital Outputs:

Enclosure: Environment: Power consumption:

UK head office Rotork Controls Limited telephone Bath 01225 733200 telefax 01225 333467 email [email protected]

USA head office Rotork Controls Inc telephone Rochester (585) 328 1550 telefax (585) 328 5848 email [email protected]

Rotork Controls Inc, Rochester, USA Rotork Controls Ltd, Bath, UK

A full listing of our worldwide sales and service network is available on our website at www.rotork.com

As part of a process of on-going product development, Rotork reserves the right to amend and change specifications without prior notice. Published data may be subject to change. For the very latest version release, visit our website at www.rotork.com

The name Rotork is a registered trademark. Rotork recognizes all registered trademarks. Published and produced in the UK by Rotork Controls Limited.