Rotork

Established Leadersin Actuation Technology

ProfibusSerial communication and control of Rotork actuators

Publication S113E

Date of issue 12/04

Process Field Bus

Profibusactuator control

Profibus-DP serial communication is ideally suited to thecontrol of Rotork actuators. A network using Profibus-DP provides a cost effective method for connectingactuators in any location to the central control systemsimply and efficiently. The Profibus-DP network canoperate over a range of communication speeds andprovides the mechanism for control of the actuator andfeedback of data about the valve.

The latest Rotork Profibus-DP option cards supportstandard DP-V0 cyclic data exchange and DP-V1 acyclicdata exchange used for diagnosis, set-up and historicaldata.

The provision of EDD files allows the latest SiemensPDM utilities to be used during configuration whilst theDTM file allows the new non-proprietary FDT utility tobe used. The standard GSD files allow all complexities ofthe 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.

Profibus®Actuator Control

For more information on Profibus consult thewebsite at http://www.Profibus.com. Profibus issupported by leading PLC manufacturers such asSiemens and Mitsubishi

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The Profibus module is fitted inside the actuatorelectrical housing and interfaces directly with theactuator electronics. Once fitted, all the normalcommands associated with moving the actuatortogether with feedback and some historical databecome available on the Profibus DP, RS485 highway.

There are a number of user settings to be made for thesystem variables and actuator performance, such as theslave address of the actuator. These are set by eitherusing the infra-red communicator link to the IQ and IQTactuator or by parameterising over the network to theappropriate registers in the module using a suitable tool.The GSD file can be edited in a simple text editor tomodify the internal parameters during Profibus start-up.

All the settings are held in non-volatile EEPROM memoryon the card

Rotork Profibus®DP-V1 Module

Profibus®DP Communication Highway

The Profibus DP module is a slave device supportingnormal cyclic communication with the PLC using V0communication and also supporting acycliccommunication using V1 communication.

The Profibus highway uses RS485, 2 wirecommunication. Up to 126 devices can be connected ona single network provided suitable repeaters areincluded. Without repeaters only 32 devices, includingthe PLC, are allowed. Address 126 is reserved for a newdevice appearing on the highway.

Dual ChannelProfibus Module

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

PLC

1200 metres at 9600 baud

Data Rate (Baud) 9600 19200 93.75k 187.5k 500k 1.5M

Maximum Segment Length 1.2km 1.2km 1.2km 1000m 400m 200m

Maximum Highway Length 10km 10km 10km 10km 4km 2km

Max No. of actuators/segment 31 31 31 31 31 31

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Address 1 Address 2 Address 3

The single channel option is the simplestimplementation of the Profibus Module. The actuator isconnected to one highway only and an additional inputfor an instrument analogue transmitter signal (currentor voltage) is provided. Two pairs of data highwayterminals are provided to ensure zero stub length insidethe actuator.

Single highway systems provide the maximum costbenefit to the installer. There is only one cable, and thehardware costs and installation costs are minimised, inaddition the engineering involved with a single channelsystem is simpler.

Profibus®Single Channel Module

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For those systems able to support the latest Profibusstandards the RedCom Dual Channel Module is fullycompliant with 2.212.

Profibus RedCom slave redundancy allows a singleactuator to support two methods of dualcommunications with a host PLC. The Profibus moduleis able to support DP-V0 cyclic communication, DP-V1acyclic communication and also the extensions to the V1protocol that allow RedCom to be implemented.

The Profibus module has two Profibus interface chipsthat allow for one or two communication channels andredundancy either by two highways (SR SystemRedundancy) or a single highway (FR FlyingRedundancy). Where redundancy of thecommunications network is required SR should be used,whilst if redundant communication to a single device isthe 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 ioon ns srL2+

The simple dual channel version caters for thoseapplications where redundant highways are being usedand the host PLC does not support a full RedComsystem. The two channels are isolated from one anotherand provide redundant communication paths withoutincluding the special functions required by RedCom. Thismodule is the ideal choice for redundant control whenthe PLC’s do not have the capability to support fullRedCom facilities.

Although two highways are used there is only a marginaladditional cost for the increased availability of the plant.There is a small increase in the field hardware andinstallation costs which is often acceptable when viewingthe overall plant requirements.

Profibus®Dual Channel Modules

RedCom Dual Channel Module

Simple Dual Channel Module

FDT – Field Device ToolFDT (Field Device Tool) technologystandardises the communication interfacebetween field devices and systems. Theutility allows off line or on lineconfiguration of a Profibus network and preparation ofdownload files for Profibus devices. In order to createthe specific application each device on the network isrequired to have a device description file called a DTM –Device Type Manager. The Rotork Profibus Module DTMallows all the settings for the Profibus card to be madeand torque profiles and settings to be viewed.

PDM – Process Device ManagerPDM is a Siemens utility which is verysimilar to FDT and allows the Profibusnetwork to be configured on or off line.The individual Profibus devices eachrequire a special Electronic Device Description (EDD) fileto be used by the utility. The Electronic Device DescriptionLanguage (EDDL) conforms to the CENELEC StandardEN50391 and EDD is a standard for PROFIBUS. The RotorkProfibus Module EDD allows all the settings for the cardto be made and also allows control and monitoring. Inaddition torque profiles and settings can be viewed.

GSD – Standard Device Description ToolThe GSD data file allows forparameterisation of the Profibus modulefrom any host PLC using cyclic V0communication. This includes the selection of the ModuleConfiguration parameter that selects the data registersto exchange in cyclic mode. Three GSD files areavailable, one for the each of the three module types.

The two versions of the Profibus module that cater forredundant communication ensure that both simple dualPLC and fully integrated redundant PLC configurationscan take advantage of system and flying redundancy.

RedCom compliant PLCs and systems require extendeddiagnostic messages that can be a nuisance to ordinarysimple PLCs. The Profibus Dual Channel module switchesmodes between simple and fully RedCom compliantapplications simply by changing a parameter set by theGSD file.

Both versions will automatically switch Primary to Backupand Backup to Primary when searching for communication.This switching will occur whenever communications onthe primary channel is lost. Communication always takesplace with a channel in Primary mode.

RedCom is only suitable for use with compliant PLC systems.

Redundant Communications – Simple and RedCom Operation

Device Description Files

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Fig 1: RedCom – Profibus Redundancy System

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

GSDGSD

Feedback and Control

The Profibus module cyclic data collected from theactuator gives information about the status of thevalve and actuator combination. In addition full digitaland analogue control of the actuator is availablewithout the need to add more components.

Acyclic data that may be collected by MS1 messagingincludes logged data when the module is in an IQ orIQT actuator. The actual data exchanged during cyclicmessages (MS0 messaging) is selected duringconfiguration by choosing the modules to beexchanged.

Profibus®Control Features

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Valve Torque Profile Data

Profibus DP-V1 messaging allows for the transfer ofbackground data between the actuator and the hostPLC or a PC on the network. V1 messages are inaddition to the V0 cyclic messages used for control andmonitoring.

The Profibus module records the torque profile of the IQand IQT actuators in both the opening andclosing directions in 22 registers that can be examinedby a host system with V1 capability. In addition a further4 registers give the number of motor starts in eachdirection and further registers give information on theactuator torque settings. An OPC server or similarlyequipped PLC, PDM or FDT ca be used to view this data.

Control Data IQ IQT QDigital Outputs:

ACTCONStop � � �

Close � � �

Open � � �

ESD � � �

Positioner enable � � �

Part stroke � � �

O_STATRelay 1* � � �

Relay 2* � � �

Relay 3* � � �

Relay 4* � � �

Analogue Outputs:Desired actuator � � �position

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

Feedback Data IQ IQT QDigital Inputs:

IDATA1Actuator moving � � �

Close limit switch � � �

Open limit switch � � �

Actuator running closed � � �

Actuator running open � � �

Remote control selected � � �

Local stop selected � � �

Local control selected � � �

IDATA2Thermostat tripped � � �

Monitor relay � � �

Valve obstructed � � �

Valve jammed � � �

Manual movement � � �

Moving inhibited � � �

Positioner moving actuator � � �

Watchdog recovery � � �

IDATA3Battery low � � �

Open interlock input � � �

Close interlock input � � �

Aux input 1 � � �

Aux input 2 � � �

Aux input 3 � � �

Aux input 4 � � �

Slow mode � � �

IDATA4GSD 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 � � �

Starts - Open 7346

Starts - Close 7782

Opening Direction Torque

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

Closing Direction Torque

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

When a Profibus slave connects to a host the GSD filevalues are used to set various parameters in the slave.For the Rotork Profibus module these parametersinclude the basis actuator performance settings fornetwork control as listed in the table.

These parameters may also be set by a master usingEDD or DTM files and in these cases there are manymore settings available including the ability to inhibitthe GSD file values from altering the settings made bythe PDM or FDT utility. Full details of the capabilities ofthese files is shown in the instruction manuals for thecards.

Parameterisation

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The configuration of the Profibus module may beselected during the start up routine for the modulewhen it connects to the highway. Profibus allows for aconfiguration telegram to be sent to the device to selectthe arrangement of the data that will subsequently beexchanged during the normal cyclic communication.

The Rotork Profibus module has 10 possibleconfigurations that allow varying amounts of data to beexchanged. The choices permit the user to optimise thecommunication so that data not required by the PLC isnot collected. The default setting of ‘Configuration 1’collects all the data from an IQ or IQT actuator.

Configuration

The Profibus RS485 communication ports are fitted withgas discharge tubes to reduce the effect of high voltagetransients on the network cables. One discharge tube isprovided per port. The protection can be enhanced bythe addition of external lightning arrestors. Theinclusion of extra components may reduce the operatingspeed for the network.

A varistor is included on the screen connection, which isisolated from earth, as a discharge path for highvoltages induced on the cable screen.

Lightning Protection

Config 1 2 3 4 5 6 7 8 9 10ACTCON � � � � � � � � �

POS_DV � � � �

O_STAT � � � � �

PORTCM �

IDATA1 � � � � � � � � � �

IDATA2 � � � � � � � � � �

IDATA3 � � � � � � � � � �

IDATA4 � � � � � � � � � �

TORQUE � � � � � �

POSITION � � � � � �

ANALOG � � � � �

DescriptionLimited Range Position Min & MaxDeadband and HystersisMotion Inhibit TimeManual Movement TravelValve Jammed TimeWatchdog Timeout & Comms Fault TimerAction on Loss of CommsLoss of signal positionAux Input Mask & ESD DI-4/Net DisableRedundancy FR/SR modeActuator type

Interface: EIA-485 (RS-485) suitable for 2 wire connection

Number of channels: 1 on Single channel, fully isolated from actuator circuits2 on Simple and RedCom Dual channel, fully mutually isolated

Address range: 0 to 126, default address 126

Data rate: 9600 baud to 1.5 Mbaud

Communication Protocol: Profibus DP, compliant with IEC61158 and EN50170

Data Communication: Cyclic DP-V0, Acyclic DP-V1 and Redcom protocol extensions

Certification: PNO certified for Profibus standard compliance

Device Description Files: EDD (for PDM), DTM (for FDT) and GSD files plus DIB icon file

Analogue Input: 1 on Single channel, 4-20mA or 0-5V dc, externally powered, 0.1% resolution and 1% linearity at 20ºC, fully isolated

User defined Digital Inputs: 4 off (IQ and IQT only), potential free input contacts

User defined Digital Outputs: 4 off contacts 5A, 120V AC or 30V, 30W DC (IQ and IQT only,requires additional relay board option)

Enclosure: Suitable for fitting within Rotork IQ, IQT and Q range actuators

Environment: -40 to +70ºC, environmentally protected by Rotork actuator double sealing to IP68

Power consumption: All Profibus module power is taken from the actuator, no externalsupply is required

Profibus®Technical Data

As part of a process of on-going productdevelopment, Rotork reserves the rightto amend and change specificationswithout prior notice.

Published data may be subject to change.

For the very latest version release, visitour website at www.rotork.com

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

A full listing of our worldwidesales and service networkis available on our website atwww.rotork.com

UK head officeRotork Controls Limitedtelephone Bath 01225 733200telefax 01225 333467email [email protected]

USA head officeRotork Controls Inctelephone Rochester (585) 328 1550telefax (585) 328 5848email [email protected] Rotork Controls Ltd, Bath, UK

Rotork Controls Inc, Rochester, USA

Dual ChannelProfibus Module