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RP GW PROFIBUS
User guide
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User guide
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KUNBUS RP GW PROFIBUS User guide

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User Manual
Gateway component for PROFIBUS
PR100069 • 03/09/2015
Table of Contents KUNBUS GmbH

Table of Contents

1 General information ........................................................................................................................3
1.1 Disclaimer..................................................................................................................................3
1.2 Notes regarding this user manual..............................................................................................4
1.3 Validity .......................................................................................................................................4
1.4 Limitation of Liability ..................................................................................................................4
1.5 Customer Service ......................................................................................................................4
2 Safe use ...........................................................................................................................................5
2.1 User ...........................................................................................................................................5
2.2 Symbols.....................................................................................................................................5
3 Overview ..........................................................................................................................................6
3.1 Functionality ..............................................................................................................................6
3.2 Control elements .......................................................................................................................7
4 Installation .....................................................................................................................................11
5 Configuration.................................................................................................................................18
6 Technical data ...............................................................................................................................26
ii Gateway component for PROFIBUS

1 General information

1.1 Disclaimer

© 2015 KUNBUS GmbH, Denkendorf (Deutschland)
The contents of this user manual have been prepared by the KUNBUS GmbH with the utmost care. Due to the technical development, the KUNBUS GmbH reserves the right to change or replace the contents of this user manual without prior notice. You can always obtain the latest version of the user manual at our homepage: www.kunbus.de
The KUNBUS GmbH shall be liable exclusively to the extent specified in General Terms and Conditions (www.kunbus.de/ agb.html).
The contents published in this user manual are protected by copyright. Any reproduction or use for the in-house requirements of the user is permitted. Reproduction or use for other purposes are not permitted without the express, written consent of the KUNBUS GmbH. Contraventions shall result in compensation for damages.
General information
Trademark protection
– KUNBUS is a registered trademark of the KUNBUS GmbH
– Windows® and Microsoft® are registered trademarks of the Microsoft,
Corp.
– Modbus is a registered trademark of the Modbus-IDA Organization.
KUNBUS GmbH Heerweg 15 c 73770 Denkendorf Deutschland
www.kunbus.de
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1.2 Notes regarding this user manual

This user manual provides important technical information that can enable you, as a user, to efficient, safe and convenient integration of the Gateways into your applications and systems. It is intended for trained, qualified personnel, whose sound knowledge in the field of electronic circuits and expertise of PROFIBUS is assumed.
As an integral part of the module, the information provided here should be kept and made available to the user.

1.3 Validity

This document describes the application of the KUNBUS Gateways with the product number:
– PR100069, Release 00

1.4 Limitation of Liability

Warranty and liability claims will lapse if:
General information
– the product has been used incorrectly,
– damage is due to non-observance of the operating manual,
– damage is caused by inadequately qualified personnel,
– damage is caused by technical modification to the product (e.g.
soldering).

1.5 Customer Service

If you have any questions or suggestions concerning this product, please do not hesitate to contact us:
KUNBUS GmbH Heerweg 15 C
+49 (0)711 3409 7077
support@kunbus.de www.kunbus.de
Gateway component for PROFIBUS
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2 Safe use

2.1 User

The Gateway may only be assembled, installed and put into operation by trained, qualified personnel. Before assembly, it is absolutely essential that this documentation has been read carefully and understood. Expertise in the following fields is assumed:
– Electronic circuits,
– Basic knowledge of PROFIBUS,
– work in electrostatic protected areas,
– Locally applicable rules and regulations for occupational safety.

2.2 Symbols

The symbols used have the following meaning:
Safe use
DANGER
CAUTION
NOTICE
Hazard
Observe this information without fail!
There is a safety hazard that can lead to serious injuries and death.
Caution
There is a safety hazard that can result in minor injuries and material damage.
Note
There is a safety hazard that can result in material damage.
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3 Overview

3.1 Functionality

The KUNBUS Gateway is a protocol converter. It allows communication between networks with different protocols.
Overview
Illustration1: Functionality
A Gateway consists of 2 gateway components that master one specific protocol each. You can combine these gateway components as you wish. This design offers you a high degree of flexibility, since you can exchange the individual gateway components at any time. The following gateway components are available as slave at present:
– CANopen
– CC-Link
– DeviceNet
– EtherCAT
– EtherNet/IP
– Modbus RTU
– Modbus TCP
– POWERLINK
– PROFIBUS
– PROFINET
– Sercos III
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3.2 Control elements

1
2
2
3
Front view
Overview
Illustration2: Front view
1 Status LEDs
for signal display.
2 2 rotary coding switches
for setting the station address.
3 Fieldbus connection
D-Sub-9 socket for the connection to PROFIBUS.
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Top
1
1
2
Overview
Illustration3: Top
1 Interconnect Port
for interconnecting the gateway components.
2 Locking clamps
for securely attaching the gateway component to the DIN rail.
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Bottom
1
2
Overview
Illustration4: Bottom
1 Mains connection
with 24 V power supply
2 Locking clamps
for securely attaching the gateway component to the DIN rail.
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3.3 Status LEDs

The signals of the status LEDs for PROFIBUS have the following meaning:
LED Designation Signal Meaning Power off Gateway not running
flashes, green Initialisation phase not yet completed on, green Operational flashes, red Correctable error (e.g. second gateway
on, red Serious error/defect in the gateway Online on, green Data is exchanged cyclically Offline red Cyclical data exchange stopped
red If the "Fault" LED additionally flashes:
red,green,
flashes
alternately Fault red A serious error has occurred. Please
red, flashes If the "Offline" LED additionally lights up
Overview
component missing)
Watchdog Timeout Firmware-Reset is executed
contact support.
red: Watchdog Timeout
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4 Installation

4.1 Preparations for interference-free operation

In the following section we have compiled some general information for you, which is important for interference-free operation. If you are already acquainted with this topic, you can skip to the next section. There, you will learn about which conditions are necessary for installing the gateway.
Cable routing
Route your cables separately in cable groups. This will protect your gateway from any unintended electromagnetic interferences.
The following groups should be routed separately:
Group Line
A Data and power supply lines for:
DC voltage below 60V
AC voltage below 25V
B Data and power supply lines for
DC voltage between 60V and 400V
AC voltage between 25 and 400V
C Power supply lines above 400V
Installation
– You can route cables of the same group together in cable ducts or
bundles.
– Cables of group A and B:
– Route the groups in separate bundles or
– in cable ducts at a minimum distance of 10 cm from each other.
– Cables of group C
– Route the groups in separate bundles or
– in cable ducts at a minimum distance of 50 cm from the other
groups.
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Shielding
Shield your cables. This will reduce any unintended electromagnetic interferences.
You can find further information on this topic in the specifications for PROFIBUS.
Potential equalization
Potential differences occur when devices are connected to different earths. These potential differences cause malfunctions.
To prevent malfunctions, you have to route an equipotential equalization conductor.
When doing so, bear in mind the following points:
– Select an equipotential equalization conductor with low impedance.
– Select as a reference value for the cross-section of the potential
equalization cable:
– 16 mm2 for potential equalization cables of up to 200 m in length
– 25 mm2 for potential equalization cables of more than 200 m in
length
– Use potential equalization cables made from copper or galvanized steel.
– Connect potential equalization cables extensively with the earth rail.
– The smallest surfaces as possible should be sandwiched between
potential equalization cables and signal cables.
Installation
If the devices of the control system are connected by shielded signal cables that are earthed on both sides, the impedance must be 10% of the shielding impedance.
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4.2 Requirements

The Gateway was designed for use in a control cabinet.
NOTICE
ü The protection class of the control cabinet must be equivalent to at least
IP54.
ü For installation in the control cabinet you need a DIN rail 35 x 7.5mm
(EN50022).
◦ Install the DIN rail horizontally in the control cabinet according to the
manufacturers' specifications. When doing so, make sure that the Gateway is at a sufficient distance from other devices.
Your gateway could get damaged if temperatures are too high.
èMake sure that the ambient temperature in the control cabinet is less
than 60°C.
èKeep the ventilation slots unobstructed. These must not be covered by
cables etc.
èMaintain sufficient distance from other devices.
Installation
Illustration5: Distances for installation
◦ Connect each gateway component individually to functional earth.
When doing so, make sure that both voltages have the same ground.
ð Your control cabinet now meets all requirements for installing the
gateway.
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4.3 Connecting Gateway Components

In order to attain a fully functional gateway, you have to interconnect both gateway components.
◦ Connect an interconnect port to each gateway component using the
plug-in jumper (product number PR100204).
◦
Installation
NOTICE
Gateway component for PROFIBUS
Illustration6: Connecting Gateway Components
ð You can now install the gateway in the control cabinet.
Only ever interconnect 2 gateway components.
If you connect additional components, severe defects could result on all devices.
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4.4 Installing Gateway in the Control Cabinet

◦ Hold the raster element of the gateway on the DIN rail.
◦ Press down the locking elements towards the gateway.
◦ Make sure that the gateway is firmly attached to the DIN rail.
Installation
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4.5 Connecting Power Supply

3
1
2
4
To connect the gateway component to the power supply, you need a spring-loaded terminal (e.g. Metz-Connect SP995xxVBNC).
You have to connect each gateway component separately to a power supply. Never interconnect functional earth and GND, otherwise the galvanic isolation between gateway GND and fieldbus ground will be removed. Instead, connect the functional earth with low impedance to the potential equalization. You can then dispense with this connection if the shield of the fieldbus cable is connected to the potential equalisation with lower impedance when entering the control cabinet.
Installation
NOTICE
Use the same power supply for both gateway components.
Different power supplies could cause a defect on both module components and malfunctions.
èEnsure in particular that no potential differences occur between the
GND pins (2).
Pin Assignment:
Pin Assignment
1 24V for module supply 2 GND 3 Do not connect! 4 Functional earth
NOTICE
Gateway component for PROFIBUS
Do not connect GND to PE
This connection could cause unintended malfunctions.
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4.6 Connecting Gateway to the Fieldbus

To connect the gateway component to PROFIBUS, you need one D­SUB 9 connector.
The pin assignment complies with the specifications of the PNO.
Pin Signal Description 1 - Not connected 2 M24 Not connected 3 RxD/TxD-PReceived/transmitted data
plus, data wire B 4 CNTR-P Control signal for repeater 5 DGND Data transmission potential
earth (galvanically isolated) 6 VP / +5V Power supply +5V for bus
connection (galvanically isol-
ated) 7 - Not connected 8 RxD/TxD-NReceived/transmitted data
minus, data wire A 9 - Not connected Protective
collar
Data transmission potential
earth
Installation
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5 Configuration

5.1 Supported Size of the Process Data

NOTICE
The gateway component for PROFIBUS supports process data of a length up to 488 bytes.
Bear in mind that the maximum length of the process data is always determined by the fieldbus with the shorter data length.
Example:
CANopen supports 512 bytes
PROFIBUS supports 488 bytes
In conjunction with PROFIBUS/ CANopen this means that 488 bytes are transmitted and updated cyclically.
Configuration
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5.2 Address Assignment

1
2
PROFIBUS - Setting Station Address
You can set the station address of the Gateways using these rotary switches.
The address or additional settings are assigned in decimal format. Thus, you have a value range from 00-99 at your disposal. Also see: Table PROFIBUS Settings.
With the two rotary switches you form a two-digit decimal number, in which switch x10 (1) determines the tens digit and switch x1 (2) determines the single digit.
Configuration
Illustration7: Coding switch
Example: You want to set the value 39.
Setting for switch 1 = 3
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Setting for switch 2 = 9
The settings execute the following actions:
Switch setting Action "01" to "98" Setting Station Address "00" Address assignment via SSA tele-
gram
"99" Firmware Reset, (e.g. to remove ad-
dress lock by SSA telegram.)
Table1: PROFIBUS Settings
Info! The new station address is first used when you restart the gateway component.
Configuration
SSA
Address Lock
The Gateway supports automatic address configuration via the "Set Slave Address" telegram of the PROFIBUS Master.
The PROFIBUS master sends SSA telegrams to the special station address 126. At the same time, a manufacturer identity number is also transmitted in addition to the station address. The manufacturer identity number is specific to a particular product. It can be obtained from the file name of the GSD file of the device. This ensures that only one device with the address 126, which has a particular ID, changes the address.
The Master also defines in this telegram whether the Gateway should no longer accept any further SSA telegrams. The Gateway processes this address lock and saves it permanently. The address is still used even after a restart of the Gateways. To remove the address lock and to change the address, you have to perform a firmware reset. Regardless of this, however, it is possible to change the address at any time using the rotary switch. The setting of the rotary switch always has priority over an address that was set by SSA.
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Bitrate
The Gateway supports the following bitrates:
9600 Bit/s 19200 Bit/s 45450 Bit/s 93750 Bit/s
187.5 Kbit/s 500 Kbit/s
1.5 Mbit/s 3 Mbit/s 6 Mbit/s 12 Mbit/s
The Gateway detects the bitrate automatically. You do not have to perform any further settings here.
Configuration
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5.3 Parameterisation

In order to exchange input and output data, the Profibus Protocol Chip must be parameterised by the PROFIBUS Master. Using the device master data (GSD) in the Master you have the option of defining the parameterisation data:
– Watchdog time,
– Affiliation to master,
– Affiliation to group,
– minimum response time Gateways to queries of the master.
The Gateway supports the application commands "Freeze Mode" and "Sync Mode".
The parameter telegram is in accordance with the PROFIBUS standard. User parameters are not allowed.
Configuration
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5.4 PROFIBUS Configuration

To configure the gateway component, you have to perform the appropriate settings with the configuration software of your PROFIBUS Master (class 1).
The PROFIBUS gateway component is created as a so-called "modular DP-V0 Slave". This means that the process data exchanged between the gateways can be structured application­specific on the profibus side.
The gateway component is equipped for this with virtual slots (installation positions). PROFIBUS controllers use these slots to address selected process data. Each slot can contain one module. Within these modules is the process data to be exchanged. Hence, you have the possibility of aggregating associated process data in one slot. This means, for example, that you can poll a compact process mapping of associated states.
If you do not want to use a slot, you can mark it with an empty module. You do not have to perform any further settings on the empty module.
Configuration
Byte order:
The process data is accessed between the gateway components in separate memory areas for input and output data. The sequence order in which the access takes place depends on the configuration of the modules.
The data of the modules is stored directly in succession in the memory area for the data exchange between gateways (see example further below).
Info! The gateway component does not support any extended diagnosis data.
The bytes are transferred to the controller in Big Endian format.
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Module Configuration
A maximum of 64 slots, each with 244 bytes for input and output data, is available for the module configuration. The modules are preset in the GSD and cannot be changed.
The following modules are available for loading the slots:
Module number Module type Size [bytes/words] Access 0 Empty module 0 ­1 Output 1 Byte 2 Output 2 Byte 3 Output 4 Byte 4 Output 8 Byte 5 Output 16 Byte 6 Input 1 Byte 7 Input 2 Byte 8 Input 4 Byte 9 Input 8 Byte 10 Input 16 Byte 11 Input/Output 1 Byte 12 Input/Output 2 Byte 13 Input/Output 4 Byte 14 Input/Output 8 Byte 15 Input/Output 16 Byte 16 Output 1 Word 17 Output 2 Word 18 Output 4 Word 19 Output 8 Word 20 Output 16 Word 21 Input 1 Word 22 Input 2 Word 23 Input 4 Word 24 Input 8 Word 25 Input 16 Word 26 Input/Output 1 Word 27 Input/Output 2 Word 28 Input/Output 4 Word 29 Input/Output 8 Word 30 Input/Output 16 Word
Configuration
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Example of Module Configuration
The following slots are to be configured:
Slot Module type Size [bytes/words] Access Module num-
ber 1 Input 1 Byte 6 2 Input 16 Byte 10 3 Output 16 Byte 5 4 Empty module 0 - 0 5 Input 1 Byte 6 6 Output 8 Byte 4 7 Input 4 Byte 8 8 Input/Output 4 Byte 13 9 Empty module 0 - 0 10 Input/Output 1 Word 26 11 Output 1 Word 16 12 Input 1 Word 21
The following tables provide the memory maps of the example and are thus used for data exchange with other gateways.
Configuration
Input data
Offset Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7
0x0000 Slot 1 Slot 2 Slot 2 Slot 2 Slot 2 Slot 2 Slot 2 Slot 2 0x0008 Slot 2 Slot 2 Slot 2 Slot 2 Slot 2 Slot 2 Slot 2 Slot 2 0x0010 Slot 2 Slot 5 Slot 7 Slot 7 Slot 7 Slot 7 Slot 8 Slot 8 0x0018 Slot 8 Slot 8 Slot 10
(L)*
Slot 10 (H*)
Slot 12 (L)*
Slot 12 (H*)
- -
Output data
Offset Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7
0x0000 Slot 3 Slot 3 Slot 3 Slot 3 Slot 3 Slot 3 Slot 3 Slot 3 0x0008 Slot 3 Slot 3 Slot 3 Slot 3 Slot 3 Slot 3 Slot 3 Slot 3 0x0010 Slot 6 Slot 6 Slot 6 Slot 6 Slot 6 Slot 6 Slot 6 Slot 6 0x0018 Slot 8 Slot 8 Slot 8 Slot 8 Slot 10
(L)*
Slot 10 (H)*
Slot 11 (L)*
Slot 11 (H)*
*(L)=Low Byte, (H)=High Byte
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6 Technical data

6.1 Technical data

Dimensions
Width 22.5 mm Height 96 mm Depth 110.4 mm Weight 90 g
Electrical Data
Power supply 24 V Power consumption during operation
(cyclical data exchange) Status display LED
Environmental Conditions
Ambient temperature 0 – 60 °C Storage temperature - 25 – 70 °C Humidity 93 % (at 40 °C) Condensing Not allowed Protection class
Control cabinet
Housing
Terminal area
100mA
IP54
IP20
IP20
Technical data
Gateway component for PROFIBUS
Assembly Data
DIN rail 35 x 7.5 mm Height 96 mm Depth 110.4 mm
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PROFIBUS Interface
Device Type Slave Protocol DP-V0 Station address 1-98 (decimal) Maximum data length
Total
Input data
Output data
488 byte
244 byte
244 byte
Technical data
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Illustration8: Side dimensions
Technical data
Gateway component for PROFIBUS
Illustration9: Front dimensions
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