Flowserve MX-QX User Manual

USER INSTRUCTIONS

MX/QX Profibus DP / PA Field Unit

FCD LMENIM2336-03 – 12/12

Installation

Operation

Maintenance

Experience In Motion

PB DPV1 / PA Field Unit Installation and Maintenance FCD LMENIM2336-03 – 12/12

Contents

1 Introduction 5

1.1 Purpose 5

1.2 How to Use this Manual 5

1.3 User Safety 6

1.4 User Knowledge 6

1.5 MX/QX PB System Capabilities and Features 7

1.5.1 General Network Specification 10

2 System Components and Installation 12

2.1 Introduction 12

2.2 Hardware 13

2.2.1 MX/QX Actuator 14

2.2.2 MX/QX PB Field Unit 14

2.2.3 Network Host Station 15

2.2.4 Network Cabling for PROFIBUS DP 16

2.2.5 Network Cabling for PROFIBUS PA 20

2.3 Other Network Components 23

2.4 Site and Network Cable Preparation 24

2.4.1 Site Preparation 24

2.4.2 Network Cable Preparation 25

2.4.3 MX/QX PB Device Installation 30

2.5 MX/QX PB Device Setup 31

2.5.1 Proportional Band 33

2.5.2 Deadband 33

2.5.3 Valve Data 33

2.6 MX/QX PB Device Description, Capabilities and Device Type Manager File Installation 34

2.6.1 MX/QX PB Device Description 34

2.6.2 MX/QX PB Device Type Manager 34

2.7 Installation Verification 34

2.7.1 Network Cabling Installation Verification 34

2.7.2 MX/QX PB Device Installation Verification 35

2.8 Configuration Confirmation 35

2.8.1 Checking Connections 35

2.8.2 View Settings 35

2.8.3 Checking the Normal Display 36

3 Software 38

3.1 PROFIBUS Protocol 38

3.2 PROFIBUS Function, Transducer, and Physical Blocks 38

3.3 Analog Input (AI) Function Block 41

3.4 Analog Output (AO) Function Block 44

3.5 Discrete Input (DI) Function Block 48

3.6 Discrete Output (DO) Function Block 50

3.7 Transducer Block 52

3.8 GSD and Electronic Device Description, and DTM Files 53

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4 Associated Documents 54

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5 How to Order Parts 55

A Appendix – Wiring Diagrams 56
B Appendix – Feature Definitions 62
C Appendix – PROFIBUS Function Block 80
Glossary 85

Tables

Table 2.1 – Maximum Segment Length 17
Table 2.2 – Total Network Length (with up to nine repeaters) 17
Table 2.3 – Recommended PROFIBUS DP Cable Parameters 17
Table 2.4 – Recommended PROFIBUS DP Cable Types 18
Table 2.5 – Recommended PROFIBUS PA Cable Parameters (Type A – shielded twisted-pair) 20
Table 2.6 – Recommended PROFIBUS PA Cable Types 20
Table 2.7 – Recommended Lengths of PROFIBUS PA Spurs (Stubs) 21
Table 2.8 – Details of Terminal Block Cable Assignments 29
Table 3.1 – Description of the Function Blocks 40

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Figures

Figure 1.1 – Typical PROFIBUS DP Network with DCS or PLC as the Host System 8
Figure 1.1a – Typical PROFIBUS DP Network with Redundancy Option (Single Master) 9
Figure 1.1b – Typical PROFIBUS DP Network with Redundancy Option (Dual Master) 9
Figure 1.2 – Typical PROFIBUS PA Network with DCS or PLC as the Host System 10
Figure 2.1 – MX/QX-05 Actuator 13
Figure 2.2 – MX/QX PB DP Field Unit 14
Figure 2.3 – MX/QX PB PA Field Unit 15
Figure 2.4 – Typical Cycle Time (Each Station with 2 Bytes I/O) 16
Figure 2.5 – Copper PROFIBUS Distance vs. Baud Rate Chart 18
Figure 2.6 – Cable Topologies 19
Figure 2.7 – Use of Shielded Cable in PROFIBUS DP 19
Figure 2.8 – PROFIBUS PA Cable Topologies 21
Figure 2.9 – Use of Shielded Cable in PROFIBUS PA 22
Figure 2.10 – PROFIBUS PA Power Supply 23
Figure 2.11 – PROFIBUS Segments 24
Figure 2.12a – PROFIBUS DP Cable Connections 25
Figure 2.12b – PROFIBUS DP Cable Connections (Redundancy Option with Single Master) 25
Figure 2.12c – PROFIBUS DP Cable Connections (Redundancy Option with Dual Master) 26
Figure 2.13 – PROFIBUS PA Cable Connections to Terminal Blocks 26
Figure 2.14 – Removing Outer Plastic Jacket 27
Figure 2.15 – Separating Cable Parts 27
Figure 2.16 – Stripping Conductors 28
Figure 2.17 – Applying Heat-Shrink Tubing 28
Figure 2.18 – Ring Tongue Connectors 29
Figure 2.19 – Connecting Network Cable to the MX/QX Terminal Block 30
Figure 2.20a – MX/QX PB DP Primary Board Mounted to MX/QX Main Board 30
Figure 2.20b – MX/QX PB DP Primary and Redundant Boards Mounted to MX/QX Main Board 30
Figure 2.21 – MX/QX PB DP Setup Sequence 31
Figure 2.22 – MX/QX PB PA Setup Sequence 32
Figure 2.23 – Normal Display, Field Unit is Communicating with Host 36
Figure 2.24a – No Communications 36
Figure 2.24b – No Communications 37
Figure 2.25 – Hardware Failure, No Communication, Bus Power Lost 37
Figure 3.1 – MX/QX Actuator Block Overview 39
Figure 3.2 – Summary of the Parameters of the Analog Input Function Block 41
Figure 3.3 – Analog Input Block 42
Figure 3.4 – Analog Input Block Scaling and Filtering 43
Figure 3.5 – Summary of the Parameters of the Analog Output Block 44
Figure 3.6 – Analog Output Function Block 45
Figure 3.7 – Analog Output Block Scaling 47
Figure 3.8 – Summary of the Parameters of the Discrete Input Function Blocks 49
Figure 3.9 – Discrete Input Function Block 49
Figure 3.10 – Summary of the Parameters of the Discrete Output Function Block 50

4

Figure 3.11 – Discrete Output Function Block 51
Figure 3.12 – PROFIBUS PA Configuration Requirements 53

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Introduction

1.1 Purpose

This manual explains how to install and operate the Flowserve Limitorque MX/QX PROFIBUS field
unit, referred to as the MX (Multi-turn)/QX (Quarter-turn) PB (PROFIBUS) field unit. Actuators
containing the PB field unit may be connected by shielded twisted-pair, or shielded two-wire cable to
form a PROFIBUS communication system network. The name PROFIBUS is derived from Process
Fieldbus. The PROFIBUS communication system is a digital, serial, two-way open bus system that
supports a variety of communication rates. The MX/QX PB unit supports a communication rate up to

1.5 Mbit/sec. This system allows a network host station such as a distributed control system (DCS)
or a programmable logic controller (PLC) to control and monitor the actuators, including the acquisi­tion of status and alarm data from each MX/QX.

1.2 How to Use this Manual

Each section provides the MX/QX PB user with information on installing and operating the MX/QX PB
field unit.

Section 1. Introduction The introduction details user safety and knowledge requirements, system
capabilities, and features.

Section 2. System Components and Installation The system components section focuses on the
description of the PROFIBUS system hardware and software components, and provides details for
installing and configuring a field unit.

Section 3. Software The software section provides details regarding the software that the MX/QX
PB uses to communicate.

Section 4. Associated Documents This section provides a list of documents on related subjects for
additional MX/QX and PROFIBUS system information.

Section 5. How to Order Parts This section provides part numbers and ordering contact
information.

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Appendix A – Wiring Diagram This section contains the detailed wiring connection information for
the MX/QX field unit.

Appendix B – Feature Definitions This section contains the Flowserve Limitorque actuator
Transducer Block I/O (Input/Output) channels and parameters.

Appendix C – PROFIBUS Function Block This section contains the PROFIBUS Function Block
parameters and descriptions.

Glossary The glossary contains a terminology list of abbreviations, acronyms and their
descriptions.

1.3 User Safety

Safety notices in this manual detail precautions the user must take to reduce the risk of personal
injury and damage to the equipment. The user must read and be familiar with these instructions
before attempting installation, operation, or maintenance. Failure to observe these precautions could
result in serious bodily injury, damage to the equipment, warranty void, or operational difficulty. The
user must follow all applicable local and state safety regulations.

Safety notices are presented in this manual in three forms:

WARNING: Refers to personal safety and alerts the user to potential danger. Failure to follow

c

warning notices could result in personal injury or death.

CAUTION: Direct the user’s attention to general precautions that, if not followed, could result

a

in personal injury and/or equipment damage.

NOTE: Highlights information critical to the user’s understanding of the actuator’s installation and
operation.

1.4 User Knowledge

It is recommended that the user read this manual in its entirety before the MX/QX PB field unit is
installed and operated.

The user needs to have a fundamental knowledge of electronics and an understanding of valve
actuators and digital control systems. Refer to the Glossary for information regarding the terms used
throughout this manual.

The following websites have documents on PROFIBUS and electric actuators:

www.PROFIBUS.com

www.flowserve.com

www.iec.ch

For PROFIBUS technology and cabling information, refer to the following documents:

6

• PROFIBUS DP Specification, IEC 61158 Type 3 and IEC 61784.

• PROFIBUS Profile – PROFIBUS PA – Profile for Process Control Devices, Version 3.02, November

2008, PROFIBUS International Order No. 3.042.

PB DPV1 / PA Field Unit Installation and Maintenance FCD LMENIM2336-03 – 12/12

• Installation Guidelines for PROFIBUS – FMS/DP Version 1.0, PROFIBUS International Order No.

2.112.

• Profibus Installation Guideline For Cabling and Assembly, Version 1.0.6, PROFIBUS International
Order No. 8.022.

• Profibus Installation Guideline For Commissioning, Version 1.0.2, PROFIBUS International Order
No. 8.032.

• Technical Guideline: PROFIBUS PA User & Installation Guideline, Version 2.2, February 2003.

• PROFIBUS Specification - Slave Redundancy Version 1.2, PROFIBUS International Order No. 2.212,

November 2004.

1.5 MX/QX PB System Capabilities and Features

Flowserve Limitorque’s MX/QX PROFIBUS (PB) field unit conforms to the open fieldbus standard
EN50170. It is suitable for use on PROFIBUS and uses a twisted-pair or two-conductor shielded cable
for connection to the network. A PROFIBUS device is an intelligent device within the actuator that
can send multiple variables to the control system over a high-resolution and distortion-free digital
communication network. The device provides control and self-test capabilities, which allow abnormal
conditions to be easily and immediately identified before an unplanned shutdown.

The MX/QX PB unit may command its actuator to: open, stop, close, move to a set position, perform
an emergency shutdown operation, read and control relays, monitor analog inputs and position,
and monitor modes and alarms. Commands to the unit come over the network from the master
network host station, which may be a Personal Computer (PC), Distributed Control System (DCS),
Programmable Logic Controller (PLC), or some other microprocessor-based device. The master is
defined as an active network node which means that it has addressing, and read and write privileges
to slave devices that are assigned to it.

Additional features and capabilities are:

• The system reduces the cost of wiring and installation by using existing wiring and multi-drop
connections, if it meets PROFIBUS requirements. It is also possible to have more than one
PROFIBUS communication network on the same cabling.

• Multiple-master operations through the use of the PROFIBUS token being passed between masters
(active nodes). Each master has its own set of slaves and may only write to those slaves.

• Master-slave operations where the master, active node, has the right to address, and send or fetch
messages from the slaves (passive nodes).

• The devices are interoperable, as devices from different suppliers communicate with one another
on the same network.

The PROFIBUS communication system supports up to 32 devices per segment, with up to 126
addressable devices with the use of repeaters.

Segmentation is used for the following reasons:

• Isolation is desired between two areas or buildings.

• Media conversion (copper to fiber or fiber to copper) is desired.

• The maximum of 32 nodes has been reached (31 + repeater).

• The maximum distance has been reached.

• It is desirable to “reform” the signal to full voltage levels (noisy environment).

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The devices used to create a segment are Repeaters for copper networks, Optical Link Modules for
glass or plastic-coated glass fiber-optic networks, and Optical Bus Terminals for plastic fiber-optic
networks. Each of these devices provides either electrical or optical isolation between segments.

The MX/QX PB field unit fits in the actuator in the sealed electrical housing compartment. There
are two different communication board options for the MX/QX PB field unit: MX/QX PB DP, which
supports PROFIBUS DP (Decentralized Periphery) RS-485 physical layer and MX/QX PB PA, which
supports PROFIBUS PA (Process Automation) IEC 1158 physical layer. The MX/QX PB DP field unit is
available with Flying and System Redundancy.

PROFIBUS DP ensures high-speed data transmission of user data, and is designed especially for
communication between a master host station and distributed devices at the field level.

PROFIBUS PA uses the expanded PROFIBUS DP protocol for data transmission and implements the
PA profile that specifies the characteristics of the field device. This transmission technique ensures
intrinsic safety and powers the field devices over the bus. PROFIBUS PA is designed for high-speed
and reliable communications, with the ability to link sensors and actuators to a common fieldbus line,
even in potentially explosive areas.

PROFIBUS PA devices can be integrated into PROFIBUS DP networks using segment couplers.

The adjustments to the MX/QX PB settings may be made locally at the actuator and over the
PROFIBUS network using a DPV1 network configuration tool.

A typical MX/QX PB DP system is shown in Figure 1.1 in a Master/Slave Configuration, Figure 1.1a
shows a typical PROFIBUS DP network with redundancy option in a single master configuration,
Figure 1.1b shows a typical PROFIBUS DP network with redundancy option in a dual master
configuration, and Figure 1.2 shows a typical MX/QX PB PA system.

Figure 1.1 – Typical PROFIBUS DP Network with DCS or PLC as the Host System

Distributed Control
System (Host)

Control Highway

PROFIBUS DP-V1
Interface

T Terminator

Power for the fieldbus devices and cable shield
grounding are discussed in Sections 2.4 and 2.5.

PROFIBUS DP Network

Terminator

T

Actuator Actuator Actuator

PBPBPBPB

Actuator

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Figure 1.1a – Typical PROFIBUS DP Network with Redundancy Option (Single Master)

Distributed Control
System (Host)

Control Highway

PROFIBUS DP-V1
Interface

Terminator

T

PROFIBUS DP Network

PBDP-A PBDP-B

Actuator

PBDP-A PBDP-B

Actuator

PBDP-A PBDP-B

Actuator

PBDP-A PBDP-B

Actuator

Figure 1.1b – Typical PROFIBUS DP Network with Redundancy Option (Dual Master)

Distributed Control
System (Host)

Control Highway

PROFIBUS DP-V1
Interface-1

Terminator

T Terminator T

Terminator

T

PROFIBUS DP Network

PBDP-A PBDP-B

Actuator

PBDP-A PBDP-B

Actuator

PBDP-A PBDP-B

Actuator

PROFIBUS DP-V1
Interface-2

PBDP-A PBDP-B

Actuator

Terminator

T

Terminator

T

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Figure 1.2 – Typical PROFIBUS PA Network with DCS or PLC as the Host System

Distributed Control
System (Host)

Control Highway

PROFIBUS PA
Interface

PA

ActuatorPAActuatorPAActuator

Point to Point Bus with spurs (or drops) Daisy Chain

Power for the fieldbus
devices and cable shield
grounding are discussed
in Sections 2.4 and 2.5.

PA

ActuatorPAActuatorPAActuator

1.5.1 General Network Specification

System Specifications:

• Communicates using the PROFIBUS DP or PROFIBUS PA protocol.

• PROFIBUS DP is V1 compliant.

• Employs high-speed communication.

• Complies with EN50170 fieldbus standard.

• PA Physical Layer with IEC1158-2.

• DP Physical Layer with RS-485.

Junction Box

PA

ActuatorPAActuatorPAActuator

Tree

PA

ActuatorPAActuatorPAActuator

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Network Specification:

Several topologies are available including point-to-point, bus, tree, ring, or a combination of these.
Network features include:

• PROFIBUS DP high-speed communications up to 1.5 Mbit/sec.

• PROFIBUS PA communications are 31.25kbits/sec (segment coupler side).

• Master/slave communications.

• Multiple-master network systems.

• Redundant PROFIBUS DP with single or multiple-master communications.

MX/QX Field Unit Specification:

The field unit mounts inside the actuator, is software controlled, and has the following features:

• Input and Output Function Blocks.

• Device descriptions – describes device and parameters.

• Network communication – compliant with EN50170.

• Configurable by user – locally and via network.

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PROFIBUS Master Specification

The PROFIBUS master is the network system host, and can be a PC, DCS, PLC, or some other
microprocessor-based device. The master is defined as the network node that has addressing, and
read/write privileges to slave devices that are assigned to it. A PROFIBUS network can have more
than one master, but one, and only one, token is active at a given time. The token provides the right
to access the transmission medium, as is passed between the active nodes (masters) with a token
telegram. The master host station acts as the bus arbiter, and does the following:

• Recognizes and adds new devices on the link.

• Removes non-responsive devices from the link.

• Distributes a priority-driven token for unscheduled cyclic transmissions between masters.

• Ensures cyclic data transferred on a periodic basis.

• Issues requests for process data from the field devices.

• Issues commands to the field devices.

High Speed Data Exchange – Startup Sequence

• Power ON / Reset – Power on / Reset of master or slave.

• Parameterization – download of parameters into the field device (selected during configuration by

the user).

• I/O Configuration – download of I/O configuration into the field device (selected during configura­tion by the user).

• Data Exchange – cyclic data exchange (I/O Data) and field device reports diagnostics.

NOTE: In the application profile definition, only Function Blocks may have cyclic parameters. Physical
Blocks and Transducer Blocks do not have cyclic parameters. PROFIBUS DP/V1 is part of the
requirement to access Acyclic parameters through the Function Block specification and is composed
of a slot number and an index number. Acyclic services are performed between two data exchange
cycles. A PROFIBUS Class 2 Master is required for acyclic data exchange (Function Blocks). An
Electronic Device Descriptor File is used in the configuration tool of the Master to gain access to the
Function Block parameters (refer to Chapter 3, Software).

Device Configuration Tool Requirements

Generally, the device configuration tool can be executed independently of the control system configu­ration tool. The general requirements are as follows:

• A PROFIBUS DP or PA network is inserted as an object of a control system project (or independent
project).

• Within that network, a device is logically attached along with object name, PROFIBUS DP/PA
address, and how many objects are to be attached.

• Editing this device will allow the user to select the type of device (actuator, sensor, etc.).

• The configuration tool will then display the extended parameters with initial values.

• These parameters may be uploaded from the device to display the actual values (if a network

connection is possible).

• New values can be entered and then downloaded to the device through the network connection.

• There will also be a method for monitoring the online parameter values.

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System Components

2

and Installation

2.1 Introduction

This section is an overview of the components used in the PROFIBUS system and their integration
with the MX/QX actuator. The MX/QX PB field unit is installed in the control compartment of the
actuator as shown in Figures 2.1a and 2.1b. The PROFIBUS network cable from the host control
station connects to the fieldbus unit at the actuator terminal block.

The Network Cabling section of this chapter is broken into two sections; PROFIBUS DP and
PROFIBUS PA.

Refer to Appendix A for detailed wiring connections.

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2.2 Hardware

Figure 2.1a – MX-05 Actuator Figure 2.1b – QX-05 Actuator

10

1

3

11

13

5

12

2

9
OPTIONAL

15

1

9

7

4

9

3

14

8

6

3

3

11

10

9

12

4

8

7

2

2

5

6

Item Description Item

1 Handwheel 1 Handwheel

2 Declutch lever 2 Declutch lever (QX-05)

3 Oil fills (dotted arrow depicts fill on declutch side) 3 Oil fill

4 Controls compartment (field unit location) 4 Controls cover

5 LCD display 5 LCD display

6 Control knobs 6 Control knob

7 Ground lug 7 Ground lug

8 Thrust/torque base 8 Baseplate

9 Conduit entries 9 Conduit entry

10 Terminal compartment 10 Terminal compartment

11 Electric motor 11 Motor

12 Nameplate 12 Certification nameplate

13 Tag nameplate

14 Oil plug

15 Stem nut stops

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2.2.1 MX and QX Actuators

The MX and QX actuators are designed for operation of ON-OFF and modulating valve applications.
The MX is a multi-turn actuator, while the QX is a quarter-turn actuator.

Both the MX and QX include the following features:

• Non-intrusive setup.

• Separately sealed terminal compartment.

• Unique absolute encoder for valve position sensing (no battery required).

• 32-character LCD for indication and calibration.

• Enhanced electronic control, monitoring, and diagnostic capabilities with Built-In Self Test (BIST)

and LimiGard™ technology.

NOTE: Recommended storage procedures are detailed in the MX and QX Maintenance and Spare
Parts Manual LMENIM2314 and LMENIM3314 respectively. Failure to comply with recommended
procedures will void the warranty. For longer-term storage, contact Flowserve for procedure and
recommendations.

2.2.2 MX/QX PB Field Unit

The MX/QX PB field unit interface board is installed in the actuator controls compartment (Figure

2.1). The MX/QX PB DP version is shown in Figure 2.2, and the MX/QX PB PA version is shown in
Figure 2.3. Each unit permits the actuator to be controlled as a slave by one or more master host
stations over their respective PROFIBUS network. The MX/QX PB DP version supports two forms of
redundancy when two PB DP field unit boards are installed in a single actuator:

a. Flying redundancy provides slave hardware redundancy in the form of an active and standby PB
DP field unit installed in each actuator. This form is commonly utilized in applications where a single
master is present.

b. System redundancy provides for both slave hardware redundancy, in the form of an active and
standby PB field unit installed in each actuator, and cable redundancy in the form of dual masters
connected to the active and standby PB DP field units.

Figure 2.2 – MX/QX PB DP Field Unit

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Note: Field unit board jumpers, JP1 and JP2, are set to “A” position on Primary board and “B” posi­tion on Redundant board.

PB DPV1 / PA Field Unit Installation and Maintenance FCD LMENIM2336-03 – 12/12

Figure 2.3 – MX/QX PB PA Field Unit

The following commands and feedback information are transmitted through this unit:

• OPEN, CLOSE, and STOP commands.

• ESD (Emergency Shutdown) commands.

• Go-to-position commands.

• Redundancy switch-over commands (Profibus DP Redundancy option).

• Position feedback.

• Actuator status, alarm, and diagnostic messages.

• User analog input feedback.

• Discrete input feedback.

• Discrete output relays.

2.2.3 Network Host Station

The PROFIBUS master is considered to be the network host station, which is typically a DCS, PC,
PLC or other microprocessor-based PROFIBUS-compliant device. In a mono-master network, the
network host device is the only active network node. This is common in a standard Master-Slave
PROFIBUS network. In a multi-master network, there are two or more active nodes. This is managed
in a token ring, where the token, a uniquely structured message, circulates continuously among the
active network nodes. In the case of multiple Masters, only one Master has read/write privileges to
its Slaves (passive nodes) at any one time, and the control token is passed continuously in ascending
order to all other active network nodes.

2.2.3.1 Token Bus and Token Passing in a Multi-Master Network

During the bus initialization and startup, the bus access control creates the token ring by recognizing
the active network nodes in ascending order. The bus access control automatically determines the
addresses of all active nodes on the bus, and records them together with its own node address,
creating a List of Active Stations. The Lowest Station Address (LSA) begins with the active token,
allowing it to fetch and send data messages to its passive slaves (referred to as polling). At comple­tion of its request frame (polling telegram), and acknowledgement or response frame returned from
the slave, the token is passed to the Next Station (NS) with a token telegram. The active node from
which the node was passed is called the Previous Station (PS). This continues until the token is being
passed from the Highest Station Address (HSA). At completion of the HSA polling telegram, the token
is passed to the LSA. The List of Active Stations is required during network operation to remove a
faulty active node, or to add a node, without disturbing data on the bus.

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2.2.3.2 Token Rotation Time

The time required for the rotation of the token to all active nodes is the token rotation time. The Time
Target Rotation (TTR) is adjustable, and is used to specify the maximum allowed time of one rotation.

2.2.3.3 Bus Cycle Time

Based on the number of slaves attached to each master and the amount of data to be transferred, a
Bus Cycle Time is calculated by the master. This is the amount of time required for a master to poll all
slaves. This, along with the Token Rotation Time, makes PROFIBUS network access deterministic.

Figure 2.4 – Typical Cycle Time (Each Station with 2 Bytes I/O)

20.0

18.0

16.0

14.0

12.0

10.0

8.0

Cycle Time (ms)

6.0

4.0

2.0

0.0

2.0

0.9

4.6

1.5 MBaud

500 kBaud

2.0

51

Number of Slaves

7.7

3.3

10 20

14.1

8.8

6.1

30

16

2.2.4 Network Cabling for PROFIBIS DP

Network cabling should be in accordance with PROFIBUS Decentralized Periphery (DP) guidelines.
To achieve immunity to electromagnetic interference, ensuring high data integrity, certain cables and
guidelines are recommended. Additionally, the following items should be taken into account when
planning the network:

• Transmission rate – Within a network, only one transmission rate can be used; the MX/QX PB DP
works at baud rates up to 1.5 Mbps.

• The level of Master and Slave redundancy, if any.

• The required number of nodes.

• The type of network components needed – terminals, connectors, connecting cables, termination.

• The type of cable to be used and its characteristics.

• The number of segments and/or repeaters.

• The overall span of the network – adding repeaters and long cable lengths can increase transmis-

sion time.

• Cable termination – active termination resistors are required at the ends of all segments.

In general, the following rules apply for PROFIBUS networks:

• The higher the baud rate, the shorter the distance allowed between nodes.

• The higher the baud rate, the shorter the maximum distance of a segment.

• The higher the baud rate, the shorter the maximum distance of an entire network.

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These distance rules (or limitations) are based on the physical characteristics of the RS-485 topology
and are not a limitation of the PROFIBUS protocol. If the distance required between two stations or
the total network distance is greater than allowed by the PROFIBUS specifications for copper cable, a
conversion to fiber-optic cable may be required. Figure 2.5 shows the baud rate versus copper cable
distance using PROFIBUS.

Table 2.1 provides the guidelines for maximum segment length versus baud rate.

Table 2.1 – Maximum Segment Length

Baud Rate 9600 to 187.5K 500K 1.5M

Maximum Segment Length (meters) 1,000 400 200

Table 2.2 provides the guidelines for maximum network length versus baud rate (assuming the use of
up to 9 repeaters).

Table 2.2 – Total Network Length (with up to nine repeaters)

Baud Rate 9600 to 187.5K 500K 1.5M

Total Network Length (meters) 10,000 4,000 2,000

NOTE: The maximum lengths are estimates and depend on the condition of the actual cable.

Tables 2.3 and 2.4 detail the various types of cable which can be used for network cabling. For
additional guidelines, see the following publications:

• PROFIBUS Networks SIMATIC NET 6GK1970-5CA20-0AA1.

• PROFIBUS Technical Guideline for PROFIBUS-DP/FMS, Version 1.0, September 1998; PROFIBUS

Guideline, Order No. 2.112.

There are different types of electrical data transfer cables:

• Standard bus cable.

• Standard bus cable with halogen-free sheath (type FRNC).

• Cable with PE sheath for use in the food and drug manufacturing industries.

• Direct buried cable with additional protective sheath for buried service.

• Trailing cable – This is a special cable type which is used where parts of the machine move

occasionally or continuously.

• Festooned cable – Comparable to a trailing cable, but has an additional strain relief element.

NOTE: Cable must meet the requirements as listed in table 2.3 to ensure reliable network
communications.

Table 2.3 – Recommended PROFIBUS DP Cable Parameters

Characteristic impedence at 3-20 MHz (ohms) 135-165

Operating capacitance (pF/m) < 30

Loop resistance (ohms/km) ≤ 110

Core diameter (mm) > 0.64

2

Core cross-section (mm

) > 0.34

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Table 2.4 – Recommended PROFIBUS DP Cable Types

FC Standard Cable (Siemens AG) 6XV1 830-0EH10

FRNC Cable (Siemens AG) 6XV1 830-0CH10

FC Food Cable (Siemens AG) 6XV1 830-0GH10

FC Ground Cable (Siemens AG) 6XV1 830-3FH10

FC Trailing Cable (Siemens AG) 6XV1 830-3EH10

Festoon Cable (Siemens AG) 6XV1 830-3GH10

PROFIBUS Data Cable (Belden Wire and Cable) 3079A/3076F

PROFIBUS DP Cable (Moeller GmbH) ZB4-900-KB1

PROFIBUS DP Cable (Kerpenwerk GmbH) 7422/7436

PROFIBUS DP Cable (ABB Automation GmbH) NDC110-NO

Figure 2.5 – Copper PROFIBUS Distance vs. Baud Rate Chart

12,000

10,000

8,000

Network

Segment

6,000

4,000

Distance (m)

2,000

1,000 1,000 1,000

0

9.6

19.2

93.75

1,000

187.5

Baud Rate (kBaud)

400

500

200

1,500 3,000

100

1,000 1,000

100

12,000

6,000

100

There are several topologies available for both redundant and non-redundant PROFIBUS networks:

• Point-to-point – A single cable from master to slave.

• Daisy chain – A single cable daisy chained in and out of each field unit device. End of segment

devices only have one incoming cable.

• Tree – Cables and electronic devices (such as repeaters or link modules) are used to branch out
from different points.

• Ring – Often implemented with fiber-optic cable which forms a circle or ring when used with
Optical Link Modules. This topology yields redundancy so that any single component fault or cable
break does not affect the network (except for the component).

• Combination of the above.

NOTE: Bus with Spurs, also referred to as stub lines, are not recommended by PROFIBUS as they can
create parallel resistance and cause disturbances and reflections on the main trunk or bus line.

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Figure 2.6 – Cable Topologies

PB DPV1 / PA Field Unit Installation and Maintenance FCD LMENIM2336-03 – 12/12

PROFIBUS
Interface

Point-to-point

Distributed Control
System (Host)

Network

Schematic topology: Details such
as terminators and power supplies
not shown

Repeater

Daisy Chain

Tree

Daisy Chain

Bus with spurs

(or drops)

2.2.4.1 Cable Shielding and Grounding for PROFIBUS DP

For best performance, PROFIBUS DP cables should be shielded. Per PROFIBUS Technical Guidelines,
the cable shield should be connected at the beginning and end of the segment. Alternatively, a 10-12
AWG ground wire may be run to each MX/QX.

In Figure 2.7, the grounding point is shown at the junction of the field devices and at each field device.

Figure 2.7 – Use of Shielded Cable in PROFIBUS DP

Field

Device

T

PROFIBUS

Interface

T

Field

Device

Field

Device

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2.2.5 Network Cabling for PROFIBUS PA

Network cabling should be in accordance with PROFIBUS Process Automation (PA) guidelines using
twisted-pair shielded cable. The data line is normally also used to supply power to the field devices.
PROFIBUS PA is a combination of the PROFIBUS-DP V1 protocol and the IEC 61158-2 transmission
technique.

The following items should be taken into account when planning the network:

• Transmission rate – Within a network, only one transmission rate can be used; typical restrictions
of PA are 31.25kbits/sec.

• The required number of nodes.

• The type of network components needed – Terminals, connectors, connecting cables, termination.

• The type of cable to be used and its characteristics.

• The number of segments and/or repeaters.

• The overall span of the network – Adding repeaters and long cable lengths can increase transmis-

sion time.

• Cable termination – Active termination resistors are required at the ends of all segments.

Tables 2.5 and 2.6 detail the recommended cable parameters and various types of cable that can be
used for network cabling. For additional guidelines, see the following publications:

• PROFIBUS Networks SIMATIC NET 6GK1970-5CA20-0AA1

• Technical Guideline – PROFIBUS PA User and Installation Guideline Version 2.2 February 2003,

PROFIBUS Guideline Order No. 2.092

Table 2.5 – Recommended PROFIBUS PA Cable Parameters (Type A – shielded twisted-pair)

Characteristic impedence 100 ohms ±20%

Maximum capacitance 2 nF/km

Loop resistance 44 ohms/km

2

Conductor cross-sectional area 0.8 mm

Maximum length of network (including spurs) 1900 m

(AWG 18)

Table 2.6 – Recommended PROFIBUS PA Cable Types

PA, Ex and Non-Ex
(ABB Automation Products GmbH)

PA, Ex and Non-Ex
(ABB Automation Products GmbH)

PROFIBUS FC Process Cable (Siemens AG) 6XV1 830-5.H10

PROFIBUS Data Cable (Beldon Wire & Cable) 3079A & 3076F

UNITRONICS Bus PA (Lapp Kabel GmbH) 2170 235 1x2x1.0

NPC080-NO

NPC150-NO

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Table 2.7 – Recommended Lengths of PROFIBUS PA Spurs (Stubs)

Number of Spur

Cables

19 to 24 30 30

15 to 18 30 60

13 to 14 30 90

1 to 12 30 120

Length of Spur Cable
Intrinsically Safe (m)

Length of Spur Cable

Non-Intrinsically Safe (m)

NOTE: The maximum lengths are estimates and depend on the condition of the actual cable.

There are several topologies for PROFIBUS networks:

• Daisy Chain – A single cable daisy chained in and out of each device. End devices only have one
cable.

• Tree – Cables and electronic devices (such as repeaters or link modules) are used to branch out
from different points.

• Star – Similar to a Tree configuration but the cables all originate from one centralized point that is
comprised of electronic devices (such as repeaters or link modules).

• Combination of the above.

Figure 2.8 – PROFIBUS PA Cable Topologies

Distributed Control
System (Host)

Control Highway

PROFIBUS
Interface

Point-to-point

Schematic topology: Details such
as terminators and power supplies
not shown

Junction

Box

Tree

Daisy Chain

Bus with spurs

(or drops)

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2.2.5.1 Cable Shielding and Grounding for PROFIBUS PA

For best performance, PROFIBUS PA cables must be shielded. When using shielded cable, connect
each cable shield to the trunk shield, and connect the overall shield to the PROFIBUS power supply
ground.

In Figure 2.9, the grounding point is shown at a connection point of power supply return.

Figure 2.9 – Use of Shielded Cable in PROFIBUS PA

Field

Device

Shielded Wire Pair

Field

PROFIBUS

Interface

T

T

Device

Connect Shield
to Ground at one
place only

Field

Device

2.2.5.2 PROFIBUS PA Power Supply

The MX/QX PB/PA board requires a nominal 24 VDC (9-32 VDC) on the PA bus to power the MX/QX
PB/PA board and make the actuator visible on the network. The required power supply is typically
connected to a segment coupler to the bus, usually located at the host end of the cable. Validate the
requirements of the segment coupler to determine actual power and voltage.

NOTE: If the actuator does not have three-phase power and the network is active, the MX/QX PB/PA
board will report this condition to the host.

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Figure 2.10 shows a typical PROFIBUS PA power supply arrangement.

Figure 2.10 – PROFIBUS PA Power Supply

Fieldbus

Power

Supply

+

-

Field

Device

PROFIBUS PA

Interface

Shielded Wire Pair

T

NOTE: Bus power supply may be integrated
with the PROFIBUS PA bus interface.

T

Field

Device

Field

Device

2.3 Other Network Components

In addition to the network cables, the following components may be used in the PROFIBUS network.
Each network is designed based on its application and therefore may not require all of these
components.

• Bus Terminal Blocks/Junction Box – Provides multiple connections to the bus (network).

• Active Bus Terminal – Provides active termination so that other stations may be powered down for

service without affecting the network.

• Connectors – Enable connections to junction boxes, terminators or other connectors. Useful in
installations where devices will be periodically disconnected or when a device is only going to be
temporarily disconnected. Some PROFIBUS connectors also include termination resistors for line
termination.

• Couplers – Provide one or several connection points to a network segment.

• Repeaters – The PROFIBUS Physical Layer (RS-485) dictates that no more than 32 nodes can exist

in a shielded twisted-pair (copper) segment. A node is defined as any station, active or passive,
that is connected to the network. Media converters (copper to fiber-optic, fiber-optic to copper) and
repeaters do not have PROFIBUS addresses and, therefore, are not included in the 126 possible
addressable nodes.

RS-485 repeaters may be used to extend the recommended distance of a segment and “reform”
the signal to full voltage levels. Repeaters are included in the total number of allowable nodes per
segment; therefore, a segment that begins with a repeater and ends with a repeater may have 30
nodes between them. The maximum number of repeaters allowed in a PROFIBUS network is nine.
(Refer to Figure 2.11.)

• Terminators – Used at each end of a PROFIBUS segment to prevent signal reflections.

• Power Supplies – Different types of power supplies can be used in a PROFIBUS network:

• Non-intrinsically safe power supply.

• Standard linear or switching power supply used with a power conditioner.

• Intrinsically safe power supply (9-32 VDC; nominal 24 VDC for PA).

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For cable connecting information on these components, refer to the following:

• Installation Guidelines for PROFIBUS – FMS/DP Version 1.0, PROFIBUS International Order No.

2.112.

• Technical Guideline: PROFIBUS PA User & Installation Guideline, Version 2.2, February 2003.

Figure 2.11 – PROFIBUS DP Segments

24

2.4 Site and Network Cable Preparation

2.4.1 Site Preparation

Prepare the installation site and associated equipment for operation of the MX/QX PB-controlled
actuators as follows:

1. Prepare a detailed site plan consisting of the following:

• Actuator locations and tag numbers.

• Junction boxes and terminal strip locations and tag numbers.

• Terminators and power supplies/conditioners, and repeaters.

2. Provide free access to the MX/QX control panel and terminal block for setup, configuration, and
troubleshooting.

3. Prepare the cable and label all wires. See Section 2.4.2.

4. Install power and control wires in separate conduits.

5. Install and verify earth grounds. The cable shields should be tied together. Ground the bus shield
at the end of each segment. The MX/QX PB unit should not connect either conductor of the cable
to ground at any point in the network. Refer to Sections 2.2.4.1 and 2.2.5.1.

NOTE: An effective local earth ground is defined as a low impedance (less than 5 ohms) path to
either:

• A ground electrode placed in the close vicinity of the actuator, free of any ground loop currents OR

PB DPV1 / PA Field Unit Installation and Maintenance FCD LMENIM2336-03 – 12/12

Figure 2.12(a) – PROFIBUS DP Cable Connections to Terminal Blocks

Figure 2.12(b) – PROFIBUS DP Cable Connections (Redundancy option with single master) to Terminal Blocks

• A safety ground, free of ground loop currents, running from the actuator back to the system
ground electrode. If the signal wiring is run on aerial cable where it may be exposed to
high-energy electrostatic discharge (such as lightning), a low impedance path to ground which
is capable of high current must be provided a short distance from the actuator as described
above OR

• A power distribution grid identifying the impact of power isolation to a particular actuator or
group of actuators.

2.4.2 Network Cable Preparation

Care must be taken during cable preparation:

• When stripping the insulation, use wire strippers that do not nick the wire.

• Use crimp ferrules to prevent stranded wires from getting loose and shorting to other wires.

• Use vibration-resistant wiring terminals that hold the ferrule securely.

2.4.2.1 Network Cable Connection to the MX/QX PB Unit

The field device is connected to the PROFIBUS network through the MX/QX terminal block.

The PROFIBUS DP network cable is connected to the terminal block as shown in Figure 2.12.

NOTE: The MX/QX PB DP device is sensitive to polarity. Cable polarity should be maintained through
all connection points.

The PROFIBUS PA network cable is connected to the terminal block as shown in Figure 2.13.

NOTE: The MX/QX PB PA device is equipped with automatic polarity identification. It is not polarity
sensitive.

Figure 2.12a – PROFIBUS DP Cable Connections to Terminal Blocks

Earth ground

Network data PBDP-A (-)

Network data PBDP-A (+)

3

14

IN

13

4

OUT

5

Network data PBDP-A (-)

Network data PBDP-A (+)

Figure 2.12b – PROFIBUS DP Cable Connections (Redundancy option with single master)

to Terminal Blocks

Earth ground

Network data PBDP-A (-)

Network data PBDP-A (+)

3

14

IN

13

Note: External jum per connection requi red between

15

16

a) Termi nals 14 & 15
b) Termi nals 13 & 16

4

OUT

5

Network data PBDP-A (-)

Network data PBDP-A (+)

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Figure 2.12(c) – PROFIBUS DP Cable Con nections (Redundancy option with dual master) to Terminal Blocks

Figure 2.12c – PROFIBUS DP Cable Connections (Redundancy option with dual master)

to Terminal Blocks

Earth ground

OUT

3
14

IN

13

4

OUT

5

1

2

15

IN

16

Network data PBDP -A(-)
Network data PBDP -A(+)

Network data PBDP -B(-)
Network data PBDP -B(+)

Figure 2.13 – PROFIBUS PA Cable Connections to Terminal Blocks

Earth ground

Network data PBPA1(-)

Network data PBPA1(+)

3

4

5

14

13

Network data PBPA1(-)

Network data PBPA1(+)

Network data PBDP -A(-)
Network data PBDP -A(+)

Network data PBDP -B(-)
Network data PBDP -B(+)

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• Shielded twisted-pair cables in compliance to PROFIBUS standards must be used.

• Shields are connected to earth ground.

PB/DP connects at the ends of each segment.
PB/PA connects at only a single point in the segment.

• Clean earth-ground connection (less than 5 ohms) provides noise protection and a clear, safe path
for surge currents.

Prepare the network cable for connection to the MX/QX terminals as follows:

CAUTION: Strip stranded conductors carefully, do not damage the strands. This will weaken

a

the conductor and can cause the conductor to break. This type of damage may not be
apparent and failure can occur without warning.

1. Remove two to three inches (5 to 8 cm) of the outer jacket of the cable as shown in Figure 2.14.

Do not cut or nick the shield or the insulated conductors.

Figure 2.14 – Removing Outer Plastic Jacket

NOTE: Excess cable should be cut and removed, not coiled or looped, to prevent noise induction into
the network.

2. Separate the cable parts. Unbraid the shield and peel back the shield to the same point where the

outer jacket was removed as shown in Figure 2.15.

Figure 2.15 – Separating Cable Parts

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