Introduction To Fieldbus
Introduction To Fieldbus
Profibus-DP
Workbook
TP 402
FRCE SF SF SF FRCE SF SF SF
BF BF
RU N RU N
ON ON
STOP STOP
RUN RUN
MRES MRES
STOP STOP
PROFIBUS-DP PROFIBUS-DP
MMC 1 5 1 5 1 5 1 5 1 5 1 5 MMC 1 5 1 5 1 5 1 5 1 5 1 5
2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6
ET 200S DP
A DDRESS
ET 200S DP
A DDRESS
OFF ON OFF ON
64 64
32 32
16 16
8 8
4 4
2 2
1 1
CPU313C-2 DP CP 343-2
SF SF
BF 0 0 PWR
DC5V 1 1 APF
FRCE 2 2 CER 14 14 14 14 14 14 14 14 14 14
RU N 3 3 AUP
STOP 4 4 CM
M M N E J L L M M N E J L L
PUSH
5 5
6 6 B 12 12 12 12 12 12
RUN
7 7 20+
STOP
MRES ∆ ∆ 10+
IN OUT SET
MPI DP A
∆ ∆
9
0 0 8
1 1 7
2 2 6
3 3 5
4 4 4
5 5 3
6 6 2
7 7 1
0
B
3
1
534 273 EN
Order No. 534 273
Description: WORKBOOK
Designation: D:LW-TP402-EN
Status: 08/2003
Authors: Monika Bliesener, Sabine Scharf
Graphic: Doris Schwarzenberger
Layout: 06.08.2003, Beatrice Huber
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2003
Internet: www.festo.com/didactic
E-Mail: [email protected]
Introduction__________________________________________________________ 5
Notes on safety and procedure _________________________________________ 15
Part A – Exercises
Part B – Fundamentals
Part C – Solutions
Part D – Appendix
The training package TP 402 Profibus-DP contains equipment and components for
automation and industrial communication. The example of a Profibus-DP is used to
impart knowledge about fieldbus technology and to acquire the professional skills
to deal with such systems.
Training contents The general training aim to be achieved with this training package is the ability
• to design
• to configure
• and to commission a Profibus-DP system
With this aim in mind, topics are also discussed that are independent of a special
bus system:
• Topology of a fieldbus system, master and slave
• Addressing of fieldbus components
• Interfaces and connections
• Data transfer
Significance of these The currently occurring, highly dynamic development of networked automation
training contents in systems facilitates new types of problem solutions for process technology,
professional practice telecontrol technology and remote maintenance.
Benefits for This training package provides the basic knowledge for the sphere of industrial
industrial practice communication, which will be required by future technicians in professional practice
for the configuration and commissioning of automated systems networked via
Profibus-DP. In this training package, the topic areas of maintenance and fault
finding are dealt with in conjunction with the elimination of faults during
commissioning.
This basic know-how will enable technicians to increase their knowledge and skills
in industrial practice during maintenance and fault finding.
Devices and components This training package enables you to adapt training packages TP 201/202 and
TP 301 to fieldbus technology and to use and network industrial components such
as valve terminals and MPS® modules from Festo Didactic into industrial systems.
Plastic tubing
Sensor cable
– 3-pin, M8 socket/4 mm SIBU, Order No. 184 123
– 3-pin, M8 plug/socket, Order No. 175 488 for cylinder sensors
– 4-pin on 3-pin M8 socket/SIBU, Order No. 184 121 for
vacuum sensor (changer module) and for sensor (magazine module)
– 4-pin on 3-pin M8 plug/socket, Order No. 532 930
– DUO connecting cable, Order No. 018 685
Profibus-DP
or
S7 EduTrainer® plus as Profibus Master
Valve terminal with Profibus-DP interface with 16-off input module, Order No. 527 432
An additional slotted assembly board, electrical power supply unit and compressed
air supply is required for the assembly of operational fieldbus systems.
Technical competence Trainees are to be familiar with the fundamentals of fieldbus systems, especially
Profibus-DP
The possibilities and areas of application for fieldbus components Part B, Chapter 1
The allocation of fieldbus systems in the hierarchical levels of a factory Part B, Chapter 1
and the requirements for different networks
The most important basic principles of data transmission within a Part B, Chapter 2
fieldbus system (addressing, telegram, protocol)
The basic bus systems in industrial use and their specific areas of Part B, Chapter 3
application
How to start?
• Provide the trainees with a brief overview of the overall system of industrial
communication with the material under Fundamentals, Part B, and a few visual
examples from industrial practice.
• Then concentrate on the main points of at least one bus system by involving
them in the exercises of this training package.
Technical terms • Explain technical terms by means of practical activities, i.e. as these occur when
practically implementing the configuration and installation of the bus system!
This method is ideal because, on the one hand, trainees are motivated at that
moment by the question arising and on the other hand it counteracts an excess of
training with theoretical material.
Fundamentals section The fundamentals section (Part B) is structured in such a way as to enable the use of
and bibliography individual chapters in order to
• introduce a topic
• consolidate and deepen the practical know-how the trainees have acquired
whilst working through an exercise.
However, you can also work through the fundamentals section as a whole, like a
book.
In the bibliography in Part D, you will find a list of literature for the consolidation of
know-how.
The PC as a working device The software-guided working method for configuration and diagnosis is
and training aid fundamental to all fieldbus systems. This therefore calls for knowledge on how to
use a PC and Windows software for training purposes. This also requires trainees to
be able to deal with initial difficulties when dealing using complex software
packages and not to become immediately discouraged by these, but to become
used to availing themselves of the on-line help. This represents an important aspect
of using one’s own initiative.
PLC programs for Complete PLC programs are available on the enclosed CD-ROM “Solutions and
Siemens STEP7 STEP7 programs for TP 402” for checking the solutions to the individual project
on CD-ROM exercises. They can be found in the form of archived STEP7 programs in the
subdirectories listed below.
Additional training software The web-based, multimedia and interactive training program Bus Studio enclosed
Bus Studio WBT with this workbook serves as an additional aid to assist trainees. It is recommended
on CD-ROM that trainees acquire the basic knowledge on fieldbus technology with this software
prior to solving the project exercises, since it provides an optimal overview of this
topic, especially for beginners. Various practical examples are visually illustrated by
means of animation. All relevant terms on the subject of bus technology can be
found in the integrated lexicon.
Depending on the level of knowledge, training time is approximately one hour. The
training contents are:
• Mode of operation and advantages of fieldbus systems
• Areas of application for different fieldbus systems
• Open and closed systems
• Technical concepts
• Data transfer standards RS 485 and RS 422
• Topologies of fieldbus systems
The following prerequisites must be met for the use of training software:
• PC with Microsoft Windows® 95/98/2000/ME/XP/NT
• Internet Explorer 5.0 or Netscape 4.7 or later
• Macromedia® Flash Player 5.0 (or later)
• 8x CD-ROM drive
Electronic documentation The solutions to the exercises in Part C of the workbook are also available in
electronic form and can be found on the CD-ROM „Solutions and STEP7 programs for
TP 402“, in the subdirectory Documentation. You will need the Acrobat Reader®
program from Adobe Systems Incorporated to be able to open the files in PDF
format. If this program is not yet installed on your PC, you can install it from the
subdirectory Documentation\Acrobat.
In Project 2, trainees start with the control and assembly of a mini system consisting
of a master and a simple slave (valve/cylinder). In this way, initial experience is
concentrated on how a master detects and addresses its slave via an address and
how bus addresses are assigned.
In Project 3, the mini system is adapted and expanded. Components are adapted
and exchanged. The trainees learn which system reaction occurs if a bus station
malfunctions or is newly added, thereby facilitating an understanding of the system.
At this point, the advantages of the bus system compared to conventional wiring
become particularly apparent. In addition, trainees get to know the specific areas of
application of a particular bus system.
Furthermore, a simple error diagnosis is to be carried out.
Projects 4 and 5 are practical exercises dealing with a more extensive problem
description. Here, the MPS stack magazine and changer module of the MPS
distribution station are to be activated. This establishes the link with an actual
process. When working through this project, a knowledge transfer takes place
whereby the acquired knowledge is applied to a situation relating to industrial
practice, i.e. the separating out of workpieces.
Trainees should work their way through this project mainly on their own initiative, by
using and applying previously acquired knowledge.
The following advice should be followed in the interest of your own safety:
• Pressurised air lines that become detached can cause accidents. Switch off
supply immediately
• Establish the tubing connections before switching on the compressed air.
• Cylinders may advance as soon as the compressed air is switched on.
• Please observe the following when working through the projects using the MPS®
magazine and changer modules:
– Fill the magazine by means of the drop-tube.
– Do not reach into these during operation!
– Stay outside of the range of the changer module during operation!
• Observe the general safety regulations (DIN 58126 und VDE 100).
• Do not operate the electrical limit switch manually during fault finding (use tool).
• Electrical limit switches are to be differentiated into two designs
– Actuation from the left
– Actuation from the right
• In the case of high piston speeds, the limit switches should only be approached
in the designated direction by the switching cam of the cylinder.
• The limit switches must not be subjected to frontal actuation
• In the pneumatic circuit diagrams of the solutions section, the cylinders are
always shown without magnetic cylinder piston, since this is only required if
magnetic limit switches are used.
The Festo Didactic equipment sets only contain cylinders with magnetic piston
rod.
• Do not exceed the permissible operating pressure.
• Use only extra-low voltage ≤24 V.
• All devices are equipped with 4 mm safety sockets/plugs. Use only cables with
safety plugs for the electrical connections.
• Pneumatic circuit design:
Connect equipment using silver-metallic plastic tubing with an external diameter
of 4 mm. To do so, insert the tubing into the QS push-in fitting up to the stop;
further securing is not necessary!
• Releasing of the QS push-in fitting:
The tubing can be released by pressing down the clamping collet (blue ring)
(uncoupling under pressure is not possible!)
• Switch off the compressed air and voltage supply prior to dismantling the circuit.
Part A – Exercises
Implementation A simple process is to be directly controlled via the local I/Os of the S7 controller.
Since programming is not a training aim in itself, the complete STEP 7 program is
provided. Trainees are merely to effect the wiring and commissioning.
The purpose of this exercise is to refresh and consolidate any previous knowledge.
Project task A CNC machining centre is to be accessed through a pneumatically operated door,
which is opened and closed by means of a pneumatic cylinder. An operator is to
open the door by pressing a pushbutton once if a workpiece is to be introduced for
machining. The operator is to close the door by pressing the pushbutton again.
The control for this pneumatically operated door is to be realised.
Name: Date:
Problem description The piston rod of a cylinder for the actuation of an automatic door is to be actuated
by means of a spring returned solenoid valve (coil 1Y1). Two proximity sensors are
to signal the positions “advanced” (1B2) and “retracted” (1B1). The cylinder is to be
actuated via a pushbutton (S1) in such a way that it extends from the end position in
the respective opposite direction. The cylinder is to operate just once each time the
pushbutton is pressed. The pushbutton must be released and pressed again in order
to trigger a second movement of the cylinder.
Work to be carried out 1. Create the electrical circuit diagram and assemble the circuit.
2. Declare the variables of the PLC program.
3. Load the PLC program to the controller.
4. Commission the system.
Name: Date:
24 V
0V
I
24 V
PLC
OV
Q
0V
Name: Date:
1 Double-acting cylinder
2 Sensor cable
1 Set of cables
1 Distributor block
Plastic tubing
Name: Date:
1B1 1B2
Pneumatic circuit diagram
1A1
1V1 4 2
1Y1
5 3
1
Name: Date:
Name: Date:
PLC program
Pneumatic door control