gefran GFW 40-300A, GFW 400-600A Installation Manual

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GFW 40-300A and GFW 400-600A

ADVANCED MODULAR POWER CONTROLLERS WITH PROFINET INTERFACE

CONFIGURATION AND PROFINET
NETWORK INSTALLATION MANUAL

Software version: 1.0.0
Code: 80561A_MSW_GFW-Profinet_07-2018_ENG

CAUTION!

The manual herein should be considered

as making up an integral part of the product, and it
must always be available to anyone interacting with it.

The manual must always accompany the product,
even in the case of sale to another user.

Installation and/or maintenance technicians must
read this manual and strictly follow the instructions
herein and found in the annexes since GEFRAN
cannot be held liable for personal, property and/or
product damages should the following conditions

not be met.

Customers are obliged to respect trade secrecy;
consequently, the following documentation and its
annexes cannot be tampered with or amended,
reproduced or sold to third parties, without
authorisation to do so from GEFRAN.

The software version this manual refers to concerns the
Modbus RTU/PROFINET Fieldbus interface board inserted
in the GFW as a PORT 2 serial communication port.

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1 • INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������������������������������3

2 • BIBLIOGRAPHIC REFERENCES ����������������������������������������������������������������������������������������������������������������������������������������������3

3 • MAIN TECHNICAL CHARACTERISTICS ����������������������������������������������������������������������������������������������������������������������������������3

4 • OVERALL COMMUNICATION ARCHITECTURE ����������������������������������������������������������������������������������������������������������������������4

5 • INSTALLATION ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������5

5.1. Pronet network connection and serial sub-net setup ........................................................................................................5

5.2. Rotary switch and dip switch selection ................................................................................................................................6

6 • PROCESS DATA STRUCTURE �������������������������������������������������������������������������������������������������������������������������������������������������7

6.1. Process data with only 1 device (slot 1) ..............................................................................................................................7

6.2. Process data with 2 devices (slot 1 + slot 2) .....................................................................................................................13

6.3. Process data with 3 devices (slot 1 + slot 2 + slot 3) ........................................................................................................13

6.4. Process data with 4 devices (slot 1 + slot 2 + slot 3 + slot 4) ............................................................................................14

7 • MODBUS PROTOCOL USE (SLOT 5 HOST COMMAND/RESPONSE) ��������������������������������������������������������������������������������15

7.1. Request channel ...............................................................................................................................................................15

7.2. Response channel ............................................................................................................................................................15

7.3. Command trigger word .....................................................................................................................................................15

7.4. Response trigger word .....................................................................................................................................................15

7.5. Command node address/response node address ............................................................................................................15

7.6. Command Modbus Function Code ...................................................................................................................................15

7.7. Response Modbus Function Code ....................................................................................................................................16

7.8. Data1, data2, data3, data4 command ...............................................................................................................................16

7.9. Data1, data2, data3, data4 response ................................................................................................................................16

7.10. Example of command 1-2 read bit towards node 3 .........................................................................................................16

7.11. Example of command 3-4 read 1 word ............................................................................................................................16

7.12. Example of command 5 write 1 word ..............................................................................................................................17

7.13. Example of command 6 write 1 word ..............................................................................................................................17

7.14. Modbus error management .............................................................................................................................................18

8 • DIAGNOSTIC MESSAGE ��������������������������������������������������������������������������������������������������������������������������������������������������������19

8.1. Serial reading error ...........................................................................................................................................................19

8.2. Serial writing error .............................................................................................................................................................19

CONTENTS

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1 • INTRODUCTION

The “GFW adv” series of modular power controllers with PROFINET Fieldbus interface is designed for rapid integration
of a large quantity of compact control units for temperature regulation and heating device control, within sophisticated
automation systems (such as PLC, Supervisory Systems, etc.) interconnected via communication networks and

protocols dened by the standard.

This manual is not designed to describe the “PROFINET” Fieldbus, as it is presumed the user is familiar with the same

and will refer if any updates are required to the above-mentioned standard or the ofcial PROFIBUS CONSORTIUM
and PROFINET International website (PI), http://www.probus.com/.

It is also presumed that the user is already familiar with the technical characteristics of GFW products, as described
in the dedicated user manuals accompanying each product, or available for download from the GEFRAN S.P.A.
website. www.gefran.com.

This user's manual will refer to GFW version in 2 variables dened as in ordination code E4/E6:

- E4 - Specic 2.2 - Stack 3.4.26.1 - Card ETH4 with Netx50

- E6 - Specic 2.3 - Stack 3.12.0.5 - Card ETH6 with Netx51

FEATURE NEW PROFINET (stack PROFINET specica 2.3) COMPARED TO OLD E4 (stack PROFINET specica

2.2)

FUNCTION DESCRIPTION

Media Redundancy Protocol

client di tipo Bumpless

Lets get:

- a time of zero reorganization of the network

- no isochronous frames lost In case of interruption of the PROFINET communication

loop

Fast Forwarding It allows a reduction of the transit delay of the PROFINET package through each

node of 50%

Dynamic Frame Packaging It allows to optimize the bandwidth, and to arrive at a theoretical cycle time for IRT

trafc equal to 32.5us instead of 1ms

2 • BIBLIOGRAPHIC REFERENCES

/1/ GFW adv 80962x, GFW INSTRUCTIONS FOR USE AND WARNINGS

/2/ GFW adv 80963x, GFW CONFIGURATION AND PROGRAMMING MANUAL

/3/ GFW_Modbus_V200, GFW - MODBUS MEMORY MAP V.2.xx

3 • MAIN TECHNICAL CHARACTERISTICS

Ethernet Baud Rate: 100 Mbit/s ...

Data transport layer: Ethernet II, IEEE 802.3

PNIO version: 2.2

Min. Device Interval: 8 msec

Address: Discovery and Conguration Protocol (DCP)

Default Input size: 48 bytes, network with 1 single GFW

Default Output size: 48 bytes, network with 1 single GFW

Max Input size: 192 bytes, network with 4 GFW

Max Output size 192 bytes, network with 4 GFW

Virtual Modbus Slot: Yes

Fast StartUp: No, Power On to Communication Ready 15 seconds

RealTimeCyclic: Class 1 & 2

Certied: No

Modbus/RTU: Master

Serial Baud Rate: 19200 bit/s

Parity: None

Data Bits: 8

Stop Bit: 1

T.serial acquisition: minimum 40mec for 16 words

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4 • OVERALL COMMUNICATION ARCHITECTURE

The communication structure implemented in the GFW communication board ensures the PROFINET network dialog
data are converted into modbus rtu packages which are sent and received via the serial line. The diagram to keep in
mind is as follows:

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5 • INSTALLATION

5�1� Profinet network connection and serial sub-net setup

UNDERSIDE VIEW VISTA FRONTALE

(*) GFW400-600

To connect the devices in a PROFINET network, use the ETH0 and/or ETH1 connectors of the integrated switch. To

connect the sub-net of the slaves unit, please refer to the diagram in the gure

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(*) GFW400-600

We recommend the use of a CAT5 Ethernet cable or above STP or UTP. The minimum distance between two
Ethernet network nodes must be less than 100m

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5�2� Rotary switch and dip switch selection

The hexadecimal rotary switches found on the GFW
indicate the node address of the slave Modbus/RTU
network that is acquired when the instrument is switched
on.

The GFW is factory-set with the rotary switches in the

“0” position and it is the customer's task to put them in

the correct position, considering that ONLY the following

combinations apply for PROFINET:

• Rotary X 10=0, Rotary X1=1 for node 1

• Rotary X 10=0, Rotary X1=2 for node 2

• Rotary X 10=0, Rotary X1=3 for node 3

• Rotary X 10=0, Rotary X1=4 for node 4

The other rotary switch positions concern specic

functions.

The GFW conguration dip-switch, as described in
manual /2/ in the chapter entitled “Description of Dip­Switches” is designed to dene the operating mode of

the instrument.

Dip “6”, in particular, when in the “ON” position, allows

the factory-set values to be restored upon “POWER

ON”.

AFTER RESTARTING THE INSTRUMENT WITH THE

FACTORY-SET PARAMETERS, REMEMBER TO SET

“6” TO THE “OFF” POSITION, SWITCH THE DEVICE

OFF AND BACK ON AGAIN.

DIP “7” MUST UNDER ALL CIRCUMSTANCES BE IN
THE “OFF” POSITION BEFORE YOU SWITCH ON

THE DEVICE!

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6 • PROCESS DATA STRUCTURE

3 input records and 3 output records of 8 words are provided for the process data exchange. These words are always

allocated in the PROFINET -Io Controller device, but in order to speed up the data exchange that occurs on the serial
line, they are handled by the PROFINET -Io slave device only if the respective eld enable record is set to true�

Furthermore, within each individual record, the variable End Of Record is used further to reduce the sending
and receiving of data present in the individual record

6�1� Process data with only 1 device (slot 1)

This conguration comprises only 1 GFW with a eldbus expansion board. The following congurations are considered:

1� GFW-M the following input data are considered by default (Slave to Master):

Input Data Mapping Proposed for Record 1

GFW-M module

Record 1 Enable = True Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUS3_1

1657 Yes

STATUS4_1

1658 Yes

STATUS_W_RO_1

1487 Yes

LD�V_1

1775 Yes

LD�A_1

1777 Yes

LD�P_1

1743 / 1904 for GFW600 Yes

OU�P_1

1026 Yes

PV / IN�A1 for GFW600

1024 / 1596 for GFW600 Yes

Input Data Mapping Proposed for Record 2

Module 2 -

Record 2 Enable = False Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUS3_2

2681 No

STATUS4_2

2682 No

STATUS_W_RO_2

2511 No

LD�V_2

2799 No

LD�A_2

2801 No

LD�P_2

2767 No

OU�P_2

2050 No

End of record / IN�A2 for

GFW600

/ 1860 for GFW600 No

Input Data Mapping Proposed for Record 3

Module 3 -

Record 3 Enable = False Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUS3_3

4729 No

STATUS4_3

4730 No

STATUS_W_RO_3

4559 No

LD�V_3

4847 No

LD�A_3

4849 No

LD�P_3

4815 No

OU�P_3

4098 No

End of record/ IN�A3 for

GFW600

/ 1867 for GFW600 No

2� GFW-M the following output data are considered by default (Master to slave):

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Output Data Mapping Proposed for Record 1

GFW-M module 1

Record 1 Enable = True Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUSW_1

1329 Yes

MAN�P_1

1276 Yes

End of record

- No

SP for GFW

1040 / - No

SP�1 for GFW

1254/ - No

SP�2 for GFW

1255/ - No
End of record - No
End of record - No

Output Data Mapping Proposed for Record 2

Module 2 -

Record 2 Enable = False Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUSW_2

2353 No

MAN�P_2

2300 No
End of record - No
End of record - No
End of record - No
End of record - No
End of record - No
End of record - No

Output Data Mapping Proposed for Record 3

Module 3 -

Record 3 Enable = False Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUSW_3

4401 No

MAN�P_3

4348 No
End of record - No
End of record - No
End of record - No
End of record - No
End of record - No
End of record - No

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3� GFW-M+GFW-E1 the following input data are considered by default (Slave to Master):

Input Data Mapping Proposed for Record 1

GFW-M module 1

Record 1 Enable = True Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUS3_1

1657 Yes

STATUS4_1

1658 Yes

STATUS_W_RO_1

1487 Yes

LD�V_1

1775 Yes

LD�A_1

1777 Yes

LD�P_1

1743 / 1904 for GFW600 Yes

OU�P_1

1026 Yes

PV / IN�A1 for GFW600

1024 / 1596 for GFW60 Ye s

Input Data Mapping Proposed for Record 2

GFW-E1 module 2

Record 2 Enable = True Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUS3_2

2681 Yes

STATUS4_2

2682 Yes

STATUS_W_RO_2

2511 Ye s

LD�V_2

2799 Yes

LD�A_2

2801 Yes

LD�P_2

2767 Yes

OU�P_2

2050 Yes

End of record / IN�A2 for

GFW600

/ 1860 for GFW600 No / yes GFW600

Input Data Mapping Proposed for Record 3

Module 3 -

Record 3 Enable = False Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUS3_3

4729 No

STATUS4_3

4730 No

STATUS_W_RO_3

4559 No

LD�V_3

4847 No

LD�A_3

4849 No

LD�P_3

4815 No

OU�P_3

4098 No

End of record/ IN�A3 for

GFW600

/ 1867 for GFW600 No

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4� GFW-M+GFW-E1 the following output data are considered by default (Master to slave):

Output Data Mapping Proposed for Record 1

GFW-M module 1

Record 1 Enable = True Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUSW_1

1329 Yes

MAN�P_1

1276 Yes
End of record - No

SP for GFW

1040 / - No

SP�1 for GFW

1254/ - No

SP�2 for GFW

1255/ - No
End of record - No
End of record - No

Output Data Mapping Proposed for Record 2

GFW-E1 module 2

Record 2 Enable = True Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUSW_2

2353 Yes

MAN�P_2

2300 Yes
End of record - No
End of record - No
End of record - No
End of record - No
End of record - No
End of record - No

Output Data Mapping Proposed for Record 3

Module 3 -

Record 3 Enable = False Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUSW_3

4401 No

MAN�P_3

4348 No
End of record - No
End of record - No
End of record - No
End of record - No
End of record - No
End of record - No

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5� GFW-M+GFW-E1+GFW-E2 the following input data are considered by default (Slave to Master):

Input Data Mapping Proposed for Record 1

GFW-M module 1

Record 1 Enable = True Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUS3_1

1657 Yes

STATUS4_1

1658 Yes

STATUS_W_RO_1

1487 Yes

LD�V_1

1775 Yes

LD�A_1

1777 Yes

LD�P_1

1743 / 1904 for GFW600 Yes

OU�P_1

1026 Yes

PV / IN�A1 for GFW600

1024 / 1596 for GFW600 Yes

Input Data Mapping Proposed for Record 2

GFW E1 module 2

Record 2 Enable = True Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUS3_2

2681 Yes

STATUS4_2

2682 Yes

STATUS_W_RO_2

2511 Ye s

LD�V_2

2799 Yes

LD�A_2

2801 Yes

LD�P_2

2767 Yes

OU�P_2

2050 Yes

End of record / IN�A2 for

GFW600

/ 1860 for GFW600 No / yes GFW600

Input Data Mapping Proposed for Record 3

3 GFW-E2 module

Record 3 Enable = True Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUS3_3

4729 Yes

STATUS4_3

4730 Yes

STATUS_W_RO_3

4559 Yes

LD�V_3

4847 Yes

LD�A_3

4849 Yes

LD�P_3

4815 Yes

OU�P_3

4098 Yes

End of record/ IN�A3 for

GFW600

/ 1867 for GFW600 No / Yes for GFW600

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6� GFW-M+GFW-E1+GFW-E2 the following output data are considered by default (Master to slave):

Output Data Mapping Proposed for Record 1

GFW M module 1

Record 1 Enable = True Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUSW_1

1329 Yes

MAN�P_1

1276 Yes
End of record - No

SP for GFW

1040 / - No

SP�1 for GFW

1254/ - No

SP�2 for GFW

1255/ - No
End of record - No
End of record - No

Output Data Mapping Proposed for Record 2

GFW-E1 module 2

Record 2 Enable = True Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUSW_2

2353 Yes

MAN�P_2

2300 Yes
End of record - No
End of record - No
End of record - No
End of record - No
End of record - No
End of record - No

Output Data Mapping Proposed for Record 3

3 GFW-E2 module

Record 3 Enable = True Data Exchanged on serial?

Variable Name

Modbus Address

(High Performance)

STATUSW_3

4401 Yes

MAN�P_3

4348 Yes
End of record - No
End of record - No
End of record - No
End of record - No
End of record - No
End of record - No

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6�2� Process data with 2 devices (slot 1 + slot 2)

All the previous congurations for only 1 device apply, keeping in mind that the operations should be carried out in
slot 2. Physically, the physical connections shown in the gure opposite are obtained. A GFW device is added to slot
2 of the master system congurator

S7

TIAPortal

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6�3� Process data with 3 devices (slot 1 + slot 2 + slot 3)

All the previous congurations for only 1 device apply, keeping in mind that the operations should be carried out in
slot 3. Physically, the physical connections shown in the gure opposite are obtained. A GFW device is added to slot
3 of the master system congurator

S7

TIAPortal

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6�4� Process data with 4 devices (slot 1 + slot 2 + slot 3 + slot 4)

All the previous congurations for only 1 device apply, keeping in mind that the operations should be carried out in
slot 4. Physically, the physical connections shown in the gure opposite are obtained. A GFW device is added to slot
4 of the master system congurator

S7

TIAPortal

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7 • MODBUS PROTOCOL USE (SLOT 5 HOST COMMAND/RESPONSE)

In slot 5, 8 bytes are available in input and 8 bytes are available in output in order to encapsulate the modbus rtu
protocol in the process data.

These data contain:

7�1� Request channel

SLOT 5 HOST COMMAND

Offset Item Name Meaning

0 Host Command byte 0-1 Command Trigger word
2 Host Command byte 2 Node address
3 Host Command byte 3 Modbus Function Code
4 Host Command byte 4 Data 1
5 Host Command byte 5 Data 2
6 Host Command byte 6 Data 3
7 Host Command byte 7 Data 4

7�2� Response channel

HOST RESPONSE

Offset Item Name Meaning

0 Host Response byte 0-1 Response Trigger word
2 Host Response byte 2 Node address
3 Host Response byte 3 Modbus Function Code
4 Host Response byte 4 Data 1
5 Host Response byte 5 Data 2
6 Host Response byte 6 Data 3
7 Host Response byte 7 Data 4

7�3� Command trigger word

Normally, in idle condition, the value of this word is the same as the RESPONSE TRIGGER WORD�
To enable the command, proceed in sequence:

1. prepare the command in the elds from Host Command byte 2 to Host Command byte 7 according to need

2. increase the value of the command trigger word

3. wait for the value of the response trigger word to be the same as the command trigger word

7�4� Response trigger word

When the command is complete or in idle condition, its value is the same as the command trigger word

7�5� Command node address/response node address

Identies the node number of the slave concerned

7�6� Command Modbus Function Code

Supports commands 1, 2 (read bit); 3, 4 (read a word); 5 (write 1 bit); 6 (write a word)

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7�7� Response Modbus Function Code

Supports commands 1, 2 (read bit); 3, 4 (read a word); 5 (write 1 bit); 6 (write a word). If the most signicant bit is set

to 1, this indicates an error in the command execution

7�8� Data1, data2, data3, data4 command

The contents of these bytes depends on the command modbus function code

7�9� Data1, data2, data3, data4 response

The contents of these bytes depends on the response modbus function code

7�10� Example of command 1-2 read bit towards node 3

The example shows command and response messages

HOST COMMAND

Host command

byte 0-1

Host command

byte 2

Host command

byte 3

Host command

byte 4

Host command

byte 5

Host command

byte 6

Host command

byte 7

Trigger++ 3 1 or 2

Bit address to

read.

Top

Bit address to

read.

Bottom

0

Number of bits

to read.

HOST RESPONSE

Host response

byte 0-1

Host response

byte 2

Host response

byte 3

Host response

byte 4

Host response

byte 5

Host response

byte 6

Host response

byte 7

Trigger =

Command

trigger

3 1 or 2

Number of bits

read

Bits read Bits read --

7�11� Example of command 3-4 read 1 word

The example shows command and response messages

HOST COMMAND

Host command

byte 0-1

Host command

byte 2

Host command

byte 3

Host command

byte 4

Host command

byte 5

Host command

byte 6

Host command

byte 7

Trigger++ 1 3 or 4

Word address

to read.

Top

Word address

to read.

Bottom

0 1

HOST RESPONSE

Host response

byte 0-1

Host response

byte 2

Host response

byte 3

Host response

byte 4

Host response

byte 5

Host response

byte 6

Host response

byte 7

Trigger =

Command

trigger

1 3 or 4

Number of
bytes read

Word read -

top

Word read -

bottom

--

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7�12� Example of command 5 write 1 word

The example shows command and response messages

HOST COMMAND

Host command

byte 0-1

Host command

byte 2

Host command

byte 3

Host command

byte 4

Host command

byte 5

Host command

byte 6

Host command

byte 7

Trigger++ 1 5

Bit address to

write.

Top

Bit address to

write.

Bottom

0 or 255 0

HOST RESPONSE

Host response

byte 0-1

Host response

byte 2

Host response

byte 3

Host response

byte 4

Host response

byte 5

Host response

byte 6

Host response

byte 7

Trigger =

Command

trigger

1 5

Bit address

written.

Top

Bit address

written.

Bottom

0 or 255 0

7�13� Example of command 6 write 1 word

The example shows command and response messages

HOST COMMAND

Host command

byte 0-1

Host command

byte 2

Host command

byte 3

Host command

byte 4

Host command

byte 5

Host command

byte 6

Host command

byte 7

Trigger++ 1 6

Word address

to write.

Top

Word address

to write.

Bottom

Data - top Data - bottom

HOST RESPONSE

Host response

byte 0-1

Host response

byte 2

Host response

byte 3

Host response

byte 4

Host response

byte 5

Host response

byte 6

Host response

byte 7

Trigger =

Command

trigger

1 6

Word address

written.

Top

Word address

written.

Bottom

Data written

- top

Data written -

bottom

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7�14� Modbus error management

In the event of an error in the execution of a modbus command, the response in the byte host response byte 2 will be
the value of the host command byte 2 plus 128:

host response byte 2=host command byte 2+128

HOST COMMAND

Host command

byte 0-1

Host command

byte 2

Host command

byte 3

Host command

byte 4

Host command

byte 5

Host command

byte 6

Host command

byte 7

Trigger++ 1 X Not signicant Not signicant Not signicant Not signicant

HOST RESPONSE

Host response

byte 0-1

Host response

byte 2

Host response

byte 3

Host response

byte 4

Host response

byte 5

Host response

byte 6

Host response

byte 7

Trigger =

Command

trigger

1 X+128 Error code^

N.B.^: The possible values for the Error code eld are:

• 1 = illegal function

• 2 = illegal address

• 3 = illegal data

• 9 = illegal number of data

• 10 = data is read only

Also available (only for the GFW device) in the case of loss of PROFINET communication, is the possibility to set
the devices connected to the following status

Fault

mode

Value Description

0 Default No Action

1

Pid Controller in software

shutdown

2

Pid Controller in manual

status

3

Pid Controller with set point

equal to SP2

S7 TIAPortal

23

80561A_MSW_GFW-Profinet_07-2018_EN

8 • DIAGNOSTIC MESSAGE

The system is capable of generating diagnostic messages following the presence of faults related to the serial
communication.

8�1� Serial reading error

In the case of problems in reading the data contained in the process data, an emergency message such as the one

shown in the gure is emitted:

Slot = 1, in the example, indicates the
device node number that features serial
communication problems

Error = shows the type of error, in the
example, communication failure

This error disappears if the
communication resumes normally

8�2� Serial writing error

In the event of writing problems, the diagnostic message shown in the gure will appear,

highlighting the following information, for instance

Slot = 1 (the error occurred on the device
with node = 1)

Error = Error writing Output record 1 (data
present in the package of record 1 is illegal
or outside the limits or there was an error
due to lack of response from the slave)

The error disappears if:

• At least one variable inside the

output record package is changed/
corrected

• All the data in the package are

written correctly

GEFRAN spa

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Phone [phone] - Fax [phone] Internet: http://www.gefran.com