Fieldbus Technologies - Industrial Communication & Control - Industrial Electronics & Software - Embedded Systems

User Manual: ESEPRO Profibus gateway for CANopen genset controls

Contents

Important user information

This manual explains how to install, operate and configure the ESEPRO. This device may only be used for the applications described in this document.

This manual is to be used with ESEPRO firmware version 1.1.

These instructions are intended for use by trained specialists in electrical installation and control and automation engineering, who are familiar with the applicable national standards and safety procedures.

Safety Precautions

Warning
ELECTRICAL HAZARD
  • This equipment must be installed and serviced only by qualified personnel. Such work should be performed only after reading this entire set of instructions.

  • Before performing visual inspections, tests, or maintenance on this equipment, disconnect all sources of electric power. Assume that all circuits are live until they have been completely de-energized, tested, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeeding.

  • Apply appropriate personal protective equipment and follow safe electrical practices.

  • Turn off all power supplying the equipment in which the ESEPRO is to be installed before installing, wiring or removing the ESEPRO.

  • Always use a properly rated voltage sensing device to confirm that power is off.

  • The successful operation of this equipment depends upon proper handling, installation, and operation. Neglecting fundamental installation requirements may lead to personal injury as well as damage to electrical equipment or other property.

Failure to follow these instructions could result in death or serious injury!

Document conventions

Throughout this manual we use the following symbols and typefaces to make you aware of safety or other important considerations:

Warning

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

Caution

Indicates a potentially hazardous situation that, if not avoided, could result in damage to equipment.

Important

Indicates information that is critical for successful application and understanding of the product.

Note

Provides other helpful user information that does not fall in above categories.

Tip

Provides supplemental user information.

Acronym

This typeface is used to introduce acronyms or product names.

Command

This typeface is used to represent commands, prompts, input fields and filenames. In the context of programming it is used for functions, variable names, constants or class names.

Placeholder

This typeface is used to represent replacable text. Replaceable text is a placeholder for data you have to provide, like filenames or command line arguments.

User input

This typeface is used to represent data entered by the user or buttons.

Screen output

Screen output or program listing

Introduction

ESEPRO is a Profibus gateway specifically designed to interface Woodward’s Easygen series genset controls with Profibus-DP networks. It interfaces via the CAN bus with the Woodward controls and is easy to configure using standard Profibus configuration tools like Simatic Manager.

A single ESEPRO added to the CAN network will make all Visualisation Data of connected Woodward CANopen controls available without adding additional load to the CAN bus communication. The Visualisation Data is buffered in the ESEPRO gateway which decouples Profibus' cyclic process I/O from the CANopen cyclic TPDO transfers.

The ESEPRO appears as a modular I/O module in the Profibus configuration tool.

The ESEPRO offers three different methods to map data into the PLC’s process I/O image to suit different application requirements and programming styles. Visualisation Data of connected Easygen and LS-5 devices can be mapped directly into the PLC’s process image. For larger data tables which exceed the Profibus I/O space, an indexed mapping similar to the Profidrive standard can be used. Alternatively access to larger data blocks via acyclic DP-V1 transfers is also possible. In addition, read and write access to the Easygen’s device Parameter IDs is possible which are internally translated to CANopen SDO transfers.

ESEPRO

Common applications include:

  • PLC connection

  • Operator panel interfacing

  • HMIs

  • SCADA integration

  • Power station automation

  • Gen set control

  • Remote control & monitoring

  • Data logging

Features

The ESEPRO gateway provides the following key features:

  • Supports Easygen-3000 Series (3500, 3400, 3200, 3100)

  • Supports Easygen-2000 Series

  • Supports Easygen-1000 Series

  • Supports LS-5

  • Supports DTSC-200

  • Addresses up to 8 Woodward controls

  • Easy configuration using Simatic Manager

  • Direct mapping of data into process I/O

  • Fast indexed access to Basic Visualisation Data table

  • Acyclic DP-V1 functions to read and write Remote Control words

  • Acyclic DP-V1 access to larger data blocks

  • Reading and Writing of device parameters

  • Internal buffer for Visualisation Data

  • Transparent handling of data guarantees future compatibility

  • Firmware upgradable via Ethernet bootloader

Quick start checklist

  • Read this set of instructions properly and in its entirety.

  • Mount the unit.

  • Wire Profibus plug.

  • Wire CAN bus plug.

  • Connect the power.

  • Configure the device with a Profibus configuration tool.

Description

The power terminals and CAN bus connector are placed on the top side of the unit. The Profibus connector and Ethernet jack are placed on the bottom side of the unit as shown in the following illustration:

ESEPRO connectors
Figure 1. Location of connectors
(1)  Clear front cover (2)  Profibus connector (3)  Ethernet jack (4)  DIN rail clip (5)  Power LED (6)  Ethernet link LED (7)  Device status LED (8)  Communication status LED (9)  Power terminals (10)  CAN bus connector

LED indicators

Four LEDs located at the front panel indicate the status of the ESEPRO. The LEDs assist maintenance personnel in quickly identifying wiring or communication errors.

A LED test is exercised at power-up, cycling each LED off, green and then red for approximately 0.25 seconds. At the same time the power-on self test of the device is performed.

The following table outlines the indicator condition and the corresponding status after the power-on self-test has been completed:

Table 1. LED diagnostic codes
LED Function Condition Indication

Power

Power

Off

No power applied to the device.

Green

Power supply OK

Link

Ethernet link

Off

No Ethernet link

Green

Ethernet link OK

Status1

Device status

Off

The device has an unrecoverable fault; may need replacing.

Flashing green at 1 s rate

Device operational but needs commissioning due to configuration missing, incomplete or incorrect.

Green

The device is operating in normal condition.

Flashing red at 1 s rate

Device operational but has a fault listed which requires acknowledgment.

Red

The device has an unrecoverable fault; may need replacing. Flashing sequence and rate of Status2 LED indicates fault class.

Status2

Network status

Flashing red at 1 s rate

No CAN comms and not in DP Data_Exch state

Off

CAN comms OK, but not in DP Data_Exch state

Flashing red/green at 1 s rate

No CAN comms but in DP Data_Exch state

Green

CAN comms OK and in DP Data_Exch state

Installation

Regulatory notes

icons/warning.png
  1. The ESEPRO is suitable for use in non-hazardous locations only.

  2. The ESEPRO is not authorized for use in life support devices or systems.

  3. Wiring and installation must be in accordance with applicable electrical codes in accordance with the authority having jurisdiction.

  4. This is a Class A device and intended for commercial or industrial use. This equipment may cause radio interference if used in a residential area; in this case it is the operator’s responsibility to take appropriate measures.

  5. The precondition for compliance with EMC limit values is strict adherence to the guidelines specified in this set of instructions. This applies in particular to the area of grounding and shielding of cables.

FCC Notice (USA only)

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

Industry Canada Notice (Canada only)

This Class A digital apparatus complies with Canadian ICES-003.

Unpacking, handling and storage

icons/important.png
  1. Please read this set of instructions. carefully before fitting it into your system.

  2. Keep all original packaging material for future storage or warranty shipments of the unit.

  3. Do not exceed the specified temperatures.

Before connecting anything

icons/warning.png
  1. Before installing or removing the unit or any connector, ensure that the system power and external supplies have been turned off.

  2. Check the system supply voltage with a multimeter for correct voltage range and polarity.

  3. Connect the power supply cable and switch on the system power. Check if the Power LED is lit.

  4. Turn off system power.

  5. Connect all I/O cables.

  6. Once you are certain that all connections have been made properly, restore the power.

DIN rail mounting and removal

The ESEPRO gateway is designed to be mounted on a 35 mm DIN rail according to DIN/EN 50022. The enclosure features a 35 mm profile at the back which snaps into the DIN rail. No tools are required for mounting. Please observe the rules outlined in [Mounting].

Clip to DIN rail

To mount the unit on a DIN rail, slot the top part of the ESEPRO into the upper guide of the rail and lower the enclosure until the bottom of the red hook clicks into place.

Removal from DIN rail

To remove the ESEPRO from the DIN rail, use a screw driver as a lever by inserting it in the small slot of the red hook and push the red hook downwards. Then remove the unit from the rail by raising the bottom front edge of the enclosure.

Mounting rules

The enclosure provides protection against solid objects according to IP 20 / NEMA Type 1 protection rating. When mounting the unit observe the following rules:

icons/caution.png
  • No water splash and water drops

  • No aggressive gas, steam or liquids

  • Avoid dusty environments.

  • Avoid shock or vibration

  • Do not exceed the specified operational temperatures and humidity range.

  • Mount inside an electrical switchboard or control cabinet.

  • Make sure there is sufficient air ventilation and clearance to other devices mounted next to the unit.

  • Observe applicable local regulations like EN60204 / VDE0113.

Powering the ESEPRO

icons/warning.png

Before connecting power please follow the rules in [Safety] and [Connecting].

Power is supplied via a 3.81 mm 2-pin pluggable terminal block located at the top side of the mounted unit (refer to [DescriptionDiagram]). The following table and picture shows the power terminal socket pinout:

Power supply connector pinout
Power supply pinout
Pin Signal Function

1

V+

Positive voltage supply (10 - 30 V DC)

2

V-

Negative voltage supply, DC power return

Caution Make sure that the polarity of the supply voltage is correct before connecting any device to the CAN port! A wrong polarity can cause high currents on the ground plane between the V- power supply pin and the ground pins of the non-isolated CAN port, which can cause damage to the device.

Wiring the Profibus interface

The Profibus interface connects the ESEPRO to a Profibus-DP master station.

The Profibus connector is a female 9-pin D-sub type, located at the bottom side of the mounted unit. It has Profibus standard IEC 61158-2 pinout as shown in the following table and picture:

Profibus connector pinout
Profibus pinout
Pin Signal Function

1

NC

2

NC

3

RxD/TxD-P

Non-inverting transceiver terminal, line B (red)

4

CNTR-P

Control of repeater direction

5

DGND

Signal ground (isolated)

6

VP

Power supply +5 V (for bus termination)

7

NC

8

RxD/TxD-N

Inverting transceiver terminal, line A (green)

9

NC

SHIELD

Shield

Wiring and installation must be carried out as specified in "Installation Guideline for PROFIBUS-DP/FMS", Order No 2.112 published by PROFIBUS & PROFINET International (PI) [PIG98].

  • Use an appropriate shielded twisted pair cable which conforms with Profibus Type A classification as per EN 50170.

  • Use a Profibus connector plug to connect to the RS-485 segment.

  • Line termination at both ends of the RS-485 bus segment is required and is best accomplished using a Profibus connector plug with activated integrated termination.

  • Maximum number of RS-485 nodes in one bus segment is 32. Bus segments can be interconnected using RS-485 repeaters.

  • In order for the cable shield to be effective at high frequencies the shield must be connected to chassis ground at both ends low inductively. In cases were there is a concern of ground currents passing along the cable shield, capacative grounding at one of the ends may be an option or an additional potential equalisation cable may be required.

Wiring the CAN interface

The CAN interface connects the ESEPRO to the Woodward CANopen based controls.

The CAN bus connector is a male 9-pin D-sub type located at the top side of the mounted unit (refer to [DescriptionDiagram]). It has industry standard CiA DS-102 pinout as shown in the following table and picture:

CAN bus connector pinout
CAN bus pinout
Pin Signal Function

1

NC

2

CAN_L

CAN_L bus line

3

CAN_GND

CAN ground

4

NC

5

NC

6

CAN_GND

CAN ground

7

CAN_H

CAN_H bus line

8

NC

9

NC

  • The network must be terminated at both ends with its characteristic impedance, typically a 120 Ohm 1/4 W resistor.

  • Maximum number of electrically connected CAN nodes is 64
    [The number of logically adressable units may be less.]
    .

  • Maximum CAN bus cable length is 250 m (820 ft) and is derated depending on bit rates and cable type.

  • Stub connections off the main line should be avoided if possible or at least be kept as short as possible. Stub connections must not have terminating resistors.

  • To ensure a high degree of electromagnetic compatibility and surge protection the cable should be twisted pairs and shielded. An additional cable conductor or pair may be used for the CAN_GND reference.

Caution Do not connect the cable shield to the CAN_GND pins or the connector shell! Use an external chassis ground connection to terminate the shield.

Connecting Ethernet

The ESEPRO is equipped with an Ethernet interface for diagnostic and maintenance purposes. The Ethernet interface is not used in normal operation. The default IP address is 169.254.0.10.

The following table describes the 10BASE-T Ethernet RJ-45 connector pinout:

Ethernet connector pinout
RJ-45 pinout
Pin Signal Function

1

TX+

Non-inverting transmit signal

2

TX-

Inverting transmit signal

3

RX+

Non-inverting receive signal

4

Internal termination network

5

Internal termination network

6

RX-

Inverting receive signal

7

Internal termination network

8

Internal termination network

  • We recommend to use Category 5 UTP network cable.

  • Maximum cable length is 100 m (3000 ft).

Profibus configuration

The ESEPRO gateway is configured using a Profibus configuration tool like Simatic Step 7’s HW Config. The required GSD file PROX0EAB.GSD can be downloaded from http://www.proconx.com/esepro/gsd

Install the GSD file according to the requirements of your Profibus configuration tool. After successful installation the ESEPRO is listed under the device family Gateway/CANopen and can be added as a node into the master’s Profibus network as shown below:

ESEPRO Profibus gateway commissioning with Step 7
Figure 2. Commissioning the ESEPRO using Simatic Step 7’s HW Config tool

The Profibus station address of the ESEPRO is configured via Profibus using your Profibus configuration tool. For example in Simatic Step 7 it is assigned from the menu PLC→PROFIBUS→Assign PROFIBUS Address… using the following dialog:

Setting Profibus station address
Figure 3. Assigning station address using Step 7’s HW Config tool

The default Profibus station address of an uncommissioned ESEPRO device is 126. Once configured, the Profibus station address is stored in non-volatile memory. The station address can be checked using the Ethernet diagnostic interface.

There is no baud rate setting, the baud rate is detected automatically and matched to the baud rate of the master station.

Mapping of Woodward devices into the process I/O

The ESEPRO gateway is a modular Profibus slave device which is organised into virtual modules. Different type of virtual modules can be configured. Each of the types facilitate different methods of data transport.

Direct mapping

The ESEPRO does support direct mapping of Data Protocol Mux objects into the process I/O. Mux objects in a Woodward device are organised in word triplets (3 × 16-bit) which are identified by a Mux number (refer to chapter Interfaces And Protocols, section CANopen Protocols of your Woodward device manual). All Woodward CANopen devices do list the available Mux numbers in the Data Protocols section of their respective manual.

To map data directly into the process I/O space of the Profibus master, a Mux Object module has to be inserted into a slot. The GSD file defines a selection of Mux object modules with different data lengths to allow insertion of a single Mux object or multiple consequtive Mux objects. A Mux object consumes 6 input bytes.

Profibus configuration using direct mapping of Mux values
Figure 4. Example configuration of direct mapping with 4 Easygens using 6 Mux objects each

The following example shows how to identify the object with Mux number 1 which contains the 16-bit value "Gen. Power Factor" and the 32-bit value "Av. Gen. Wye-Voltage".

Data Protocols from Easygen-3500 manual
Figure 5. Data Protocols from Easygen-3500 manual
UMESEPRO__1.png
Figure 6. Example how the Easygen-3000 Mux object 1 maps into the PLC iput area

Once a Mux object module is inserted, it has to be parametrized with a COB-ID and the Mux number. The COB-ID links the Mux object to a Woodward device’s TPDO channel. The Mux value defines the which entry of the Data Protocol is to be mapped. In case of multiple Mux objects it defines the start entry of the array of Mux objects to be mapped.

Parameter assignment
Figure 7. Parameter assignment of a Mux object module

The following module parameters can be configured:

COB-ID

COB-ID of the TPDO which transmits the Data Protocol

Mux

Data Protocol Mux number (Data byte 0) of object to be mapped

The I/O space of Profibus-DP is limited to 244 bytes and compared to the large amount of data available in a Woodward control only a relativley small number of data values can be mapped directly into the I/O space. Larger amount of data can be accessed via DP-V1 transfers or using indexed access which is described in the next section.

Indexed mapping

In a typical installation for each connected Woodward control a device module is added to the process I/O. A device module consumes 7 bytes in the process I/O space and facilitates CANopen TPDO and SDO communciation between the Woodward control and the Profibus master station. A device module allows access to data via cyclic DP-V0 communication and also via acyclic DP-V1 communication. Access to data is performed in an indexed manner.

Once a device module is inserted into a slot it is automatically linked to the Woodward device with the Node-ID matching the slot number. It is therefore recommended to insert Easygen #1 into slot 1, Easygen #2 into slot 2 and so forth. Automatic linking makes configuration much faster and your module layout matches the structure of your CANopen network.

Profibus configuration for 3 Easygen and 2 LS-5 modules
Figure 8. Example configuration with 3 Easygens (Node-ID 1, 2 and 3) and 2 LS-5 (Node-ID 11 and 12)

There are however applications where automatic linking is not practical and the link to a particluar Woodward device can be set using the following module parameters:

Node-ID

CANopen Node-ID of the Woodward device. Leave at 0 for automatic linking based on slot number.

COB-ID

COB-ID of the TPDO which transmits the Data Protocol. Leave at 0 for automatic linking based on slot number.

Generic Woodward device module

In addition to the standard device modules for Easygens, LS-5 and DTSC-200, the GSD file defines a generic device module which can be used to add non-standard Data Protocols or other Woodward devices for which no specific module exists. The following module parameters have to be configured:

Node-ID

CANopen Node-ID of the Woodward device.

COB-ID

COB-ID of the TPDO which transmits the Data Protocol.

Number of Mux objects

Configure the number of Mux objects this device is publishing. The Easygen-3000 for example publishes 90 Mux objects for Data Protocol 5003 and 30 Mux objects for Data Protocol 4103.

Protocol ID

Protocol ID of the transmitted Data Protocol

Example for Data Protocol 4103 (J1939 Standard Visualization)

To access Data Protocol 4103 (J1939 Standard Visualization), first look up its documentation in the Easygen-3000 Series manual and extract the Protocol ID and the Number of Mux objects this protocol is publishing from the table:

Easygen manual extract with J1939 protocol
Figure 9. Extract from Easygen manual with Data Protocol 4103 J1939 Standard Visualization

Use Woodward’s ToolKit to configure a second TPDO in the Easygen with protocol 4103 and set it to a unique COB-ID within the range 432 - 511 as shown below:

J1939 TPDO configuration with Woodward ToolKit
Figure 10. J1939 Data Protocol TPDO configuration with Woodward ToolKit

Then add a Generic Woodward device module with the following parameter assignment to your Profibus configuration:

Node-ID = Parameter 8950 Node-ID of the Easygen COB-ID = 432 Protocol ID = 4103 Number of Mux objects = 30 (add 1 to the highest Mux ID of this Data Protocol)
Generic module parameter assignment
Figure 11. Parameter assignment for a Generic Woodward device module to access Easygen’s J1939 Standard Visualization data protocol
RPDO Profile

In addition to Data Protocols it is also possible for a Woodward device to publish individual parameter IDs using TPDOs. All Woodward CANopen devices offer multiple TPDO (Transmit PDO) channels. While the first TPDO channel is typically used for the Mux based visualisation data, the remaining TPDO channels can be configured application specific. The ESEPRO gateway supports reading application specific PDO messages using the RPDO module.

Configuration of Woodward device

The following parameters have to be set at the Woodward control:

COB-ID

Set to unique COB-ID within the range of 432 (1B0hex) to 511 (1FFhex).

Transmission type

Set to 255 for cyclic

Event timer

Set to desired update rate, for example 1000 ms

Selected data protocol

Must be 0

Number of Mapped Objects

1 - 4

1. Mapped Object

Parameter ID of data item

2. Mapped Object

Parameter ID of data item

3. Mapped Object

Parameter ID of data item

4. Mapped Object

Parameter ID of data item

Configuration of ESEPRO device

The RPDO module parameters must be set to match the settings made on the Woodward device.

COB-ID

Configure the COB-ID to match the TPDO. Must be in the range of 432 (1B0hex) to 511 (1FFhex).

Profibus operation

Organisation of the data in Woodward CANopen devices

Data in Woodward CANopen devices is accessible to external devices either as single parameter value or as block data part of a Data Protocol.

The technical method how these two classes of data is transported is quite different.

Retrieving single parameter values involves acyclic CANopen SDO transfers. Accessing Data Protocol values is based on cyclic CANopen TPDO publishing.

The SDO transfer method is used mainly for Configuration and Remote Control. The TPDO message method is used to publish a selected list of Visualisation Data Protocols identified by a Protocol ID.

UMESEPRO__2.png
Figure 12. Organisation of data in Woodward controls

Processing Data Protocol data through the ESEPRO gateway is more efficient and faster than using single parameter values because Data Protocol data is internally buffered and instantly available.

All Woodward CANopen devices offer several Data Protocols which can be published via CANopen. The Basic Visualisation data protocol is usually configured as default data protocol.

The following table lists the most commonly used Data Protocols:

Table 2. CANopen Data Protocols
Woodward CAN device Data protocol Topic

Easygen-3000 series

5003
[Enabled by default]

Basic Visualisation

Easygen-3000 series

4103

J1939 Standard Visualization

Easygen-3000 series

4104

J1939 Scania S6 Visualization

Easygen-3000 series

4105

J1939 Deutz EMR2 Visualization

Easygen-3000 series

4110

J1939 MTU ADEC Visualization

Easygen-3000 series

5004

Generator Values Visualization

Easygen-3000 series

5005

Mains Values Visualization

Easygen-3000 series

5011

Alarm Values Visualization

LS-5

5103

Basic Visualisation

LS-5

6003

LS-5 Communication

Easygen-1000 series

4000 or 4003

Easygen-2000 series

5100 or 5101

DTSC-200

4700 or 4701

65000

IKD 1 - external DIs/DOs 1 through 8

65001

IKD 1 - external DIs/DOs 9 through 16

65002

IKD 1 - external DIs/DOs 17 through 24

65003

IKD 1 - external DIs/DOs 25 through 32

For a Data Protocol to be available through the ESEPRO gateway, it must be enabled in the TPDO configuration of the Woodward CANopen device.

Addressing of Woodward CANopen devices

The individual Woodward devices on the CAN bus are identified by two different means. Firstly each Woodward CANopen device is identified by a CANopen Node-ID. The Node-ID is used for single parameter value SDO transfers. The Data Protocol values are associated to a particular Woodward CANopen device using a TPDO COB-ID rather the CANopen Node-ID. So it is important to have both a unique Node-ID and a unique TPDO COB-ID configured for each device.

Methods of data transfer

The Profibus-DP standard offers two different methods of data transfer. Cyclic Data Transfer of up to 244 bytes per Profibus-DP Slave device and Acyclic Data Transfer for bulk data which are transferred in blocks of up to 240 bytes.

The Easygen and LS-5 devices offer a large catalogue of process data which exceeds the cyclic transfer limit of 244 bytes.

To overcome this limitation the ESEPRO offers two distinct data transfer methods:

  • Profile style transfers using a small 7 byte request/reply buffer in the process I/O area and

  • DP-V1 transfers using acyclic communication services.

DP-V0 indexed data mapping

The method of using indexed data mapping is similar to the method used by the Profidrive standard. A small 7-byte buffer area is defined in the process I/O area. The PLC then selects a data item to be transferred by putting a command and an ID number into the output buffer and then polls an input buffer until the queried data item has been received.

This method has the advantage that it can be used with DP-V0 masters as no DP-V1 capabilities are required. The programming effort is also quite minimal.

Read Mux object
UMESEPRO__3.png
Cmd

Set to the identifier of the Mux object to be read

Status

If in range from 0 to 99 indicates the Mux identifier corresponding to the three input words. 255 indicates a PDO communication time-out.

Word 1

Data byte 1,2 of Mux values

Word 2

Data byte 3,4 of Mux values

Word 3

Data byte 5,6 of Mux values

Example

We like to read the three generator currents of the Easygen-3500. The generator currents are contained in Mux objects 11, 12 and 13 of data protocol 5003 as shown below:

Extract from Easygen-3500 manual
UMESEPRO__4.png
Figure 13. Message sequence chart for reading the three generator currents
Read parameter
UMESEPRO__5.png
Cmd

240

Para ID

Parameter ID

Status

241 = 8-bit parameter value received
242 = 16-bit parameter value received
244 = 32-bit parameter value received
245 = SDO transfer in progress
248 = Woodward device returned an SDO error code
249 = SDO response time-out error
255 = PDO communication time-out error

Value

Parameter value if Status is 241, 242 or 244. Length is Status minus 240.

UMESEPRO__6.png
Figure 14. Message sequence chart for reading parameter ID 1752 "Gen. rated active power"
Write parameter
UMESEPRO__7.png
Figure 15. Layout of process I/O image for writing Parameters
Cmd

241 = Write 8-bit parmater value
242 = Write 16-bit parmater value
244 = Write 32-bit parmater value

Para ID

Parameter ID

Value

Parameter value to be transferred. Length is determined by Cmd byte.

Status

240 = Parameter value transmitted successfully
245 = SDO transfer in progress
248 = Woodward device returned an SDO error code
249 = SDO response time-out error
255 = PDO communication time-out error

Important Unless the Parameter ID is in the remote control range from 500 to 599 a CAN Interface password with the appropriate code level must be set before the parameter change is accepted by the Woodward control.
UMESEPRO__8.png
Figure 16. Message sequence chart for writing parameter ID 10402 "Password for CAN Interface 1"
UMESEPRO__9.png
Figure 17. Message sequence chart for writing parameter ID 1752 "Gen. rated active power"

DP-V1 functions

The ESEPRO supports the following services for acyclic communication in the Profibus DP network:

  • Communication between class 1 master and slave (MS1):

    • Data acyclic reading (DS_Read)

    • Data acyclic writing (DS_Write)

  • Communication between class 2 master and slave (MS2):

    • Initiates the connection (Initiate)

    • Data acyclic reading (DS_Read)

    • Data acyclic writing (DS_Write)

    • Aborts the connection (Abort)

The Profibus DP-V1 DP_READ function can be used to read larger blocks of data. In addition Remote Control words can be written and read using DP_WRITE and DP_READ.

Writing/reading data with STEP 7

You can access the ESEPRO data sets via the user program.

  • Reading Visualisation data, Remote Control words and Parameter:

    • S7 master: By calling up SFC 59 "RD_REC"

    • S7-DPV1 master: By calling up SFB 52 "RDREC" or SFC 59 "RD_REC"

  • Writing Remote Control words:

    • S7 master: By calling up SFC 58 "WR_REC"

    • S7-DPV1 master: By calling up SFB 53 "WRREC" or SFC 58 "WR_REC"

Read MUX objects
DP-V1 Service

5Fhex DP_Read

In

Slot

1-127, slot number of a device module

Index

0-99, set to MUX Byte of first MUX object to read

Length

6-240, set to number of MUX ojects expected to be read x 6

Out

Length

6-240, length of MUX array actually read in bytes

Data

Variable size record holding the read MUX objects

Read Remote Control word
DP-V1 Service

5Fhex DP_Read

In

Slot

1-127, slot number of a device module

Index

100-199, set index to Remote Control Word ID minus 400

Length

2 or 4, set to size of Remote Control Word which can be either 2 or 4 bytes

Out

Length

2 or 4, length of the read result in bytes

Data

Variable size field holding the read result

UMESEPRO__10.png
Figure 18. Message sequence chart for reading Remote Control Word 1 (Parameter ID 503)
Write Remote Control word
DP-V1 Service

5Ehex DP_Write

In

Slot

1-127, slot number of a device module

Index

100-199, set index to Remote Control Word ID minus 400

Length

2 or 4, set to size of Remote Control Word which can be either 2 or 4 bytes

Data

Variable size field holding the remote control word content

Note No interface password is required for writing to Remote Control Words.
UMESEPRO__11.png
Figure 19. Message sequence chart for setting Remote Control Bit 1 (Parameter ID 556)
Remote Control Word IDs
Table 3. Relationship between Remote Control Word ID and DP-V1 Index

Name

Parameter ID

Index

Length

Encoding

Used for

Remote Control Word 1

503

103

2

Bit 0: Remote start
Bit 1: Remote stop
Bit 2: write always 0
Bit 3: write always 0
Bit 4: Alarm acknowledgment
Bit 5-15: internal use

Easygen remote start/stop/alarm acknowledge

Remote Control Word 2

504

104

2

Bit 0-3: internal use
Bit 4: Remote V setpoint [04.37]
Bit 5: Remote F setpoint [04.38]
Bit 6: Remote PF setpoint [04.39]
Bit 7: Remote P setpoint [04.40]
Bit 8-15: internal use

Easygen activate remote setpoints 2

Remote Control Word 3

505

105

2

LS-5 or Easygen, freely configurable in Logics Manager
[The bits of this control word can alternatively be written individually using Paremeter ID 541 - 556]

Remote Active Power Setpoint

507

107

4

kW × 10

Easygen Analog Manager data source [05.06]

Remote Power Factor Setpoint

508

108

2

cos φ × 1000

Easygen Analog Manager data source [05.12]

Remote Frequency Setpoint

509

109

2

Hz × 100

Easygen Analog Manager data source [05.03]

Remote Voltage Setpoint

510

110

4

V × 1

Easygen Analog Manager data source [05.09]

Remote Reset Alarm

522

122

2

Parameter ID of alarm

Resetting specific alarms

Remote Control Bit 16

541

141

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.59]

Remote Control Bit 15

542

142

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.58]

Remote Control Bit 14

543

143

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.57]

Remote Control Bit 13

544

144

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.56]

Remote Control Bit 12

545

145

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.55]

Remote Control Bit 11

546

146

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.54]

Remote Control Bit 10

547

147

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.53]

Remote Control Bit 9

548

148

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.52]

Remote Control Bit 8

549

149

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.51]

Remote Control Bit 7

550

150

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.50]

Remote Control Bit 6

551

151

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.49]

Remote Control Bit 5

552

152

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.48]

Remote Control Bit 4

553

153

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.47]

Remote Control Bit 3

554

154

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.46]

Remote Control Bit 2

555

155

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.45]

Remote Control Bit 1

556

156

2

0=off, 1=on

LS-5 or Easygen Logics Manager command variable [04.44]

Remote Control Examples
Send start command to Easygen
Index = 103
Length = 2
Request Data = 0001hex
Send stop command to Easygen
Index = 103
Length = 2
Request Data = 0002hex
Alarm reset Easygen
  1. Set signal

    Index = 103
    Length = 2
    Request Data = 0010hex
  2. Reset signal

    Index = 103
    Length = 2
    Request Data = 0000hex
Note Alarm reset requires generation of two rising edges which is achieved by first setting the command bit, clearing it again and then repeating this sequence. The first set/clear sequence disables the horn, the second finally resets the alarm.
Acknowledge "Mains undervoltage 1" alarm (Parameter ID 3012) on Easygen
Index = 122
Length = 2
Request Data = 3012dec
Set active power setpoint of 100 kW for Easygen
Index = 107
Length = 4
Request Data = 1000dec
Set power factor setpoint to c0.71 (capacitive) for Easygen
Index = 108
Length = 2
Request Data = -710dec or FD3Ahex
Set power factor setpoint to i0.99 (inductive) for Easygen
Index = 108
Length = 2
Request Data = 990dec or 03DEhex
Write Remote Control Word 3 on LS-5 to set Remote Control Bit 1
Index = 105
Length = 2
Request Data = 0001hex
Set Remote Control Bit 1 on LS-5
Index = 156
Length = 2
Request Data = 1
Clear Remote Control Bit 1 on LS-5
Index = 156
Length = 2
Request Data = 0

Configuration of connected Woodward controls

The ESEPRO has been designed to keep the configuration effort required to connect the gateway with Woodward CANopen devices to a minimum. In most situations no additional configuration is necessary to get the ESEPRO communicating with an Easygen-3000 series control. Other Woodward controls like the DTSC-200 may require some configuration changes for settings like CAN baudrate and the TPDO COB-IDs.

The following list of Woodward CAN device parameters affect the operation of the ESEPRO gateway and their setting should be checked during installation and commissioning:

  • CAN baudrate

  • CANopen Node-ID

  • COB-ID of Transmit PDOs (TPDO)

  • Data Protocol of the Transmit PDOs (TPDO)

CAN baudrate

For all CAN devices the CAN baudrate must be set to 250 kBit/s.

CANopen Node-ID and TPDO COB-ID

To minimise the configuration effort, there is a fixed relationship between the CANopen Node-ID and the TPDO COB-ID which is documented in the table below. The relationship follows the rules of the CANopen Predefined Connection Set PDO assignments. Easygen-3000 and LS-5 controls use the COB-ID range from 385 to 432 by default. For the DTSC-200 the preconfigured range must be changed to be in the range of 385 to 432.

Table 4. CANopen Node-ID & COB-ID relationship
CANopen Node-ID TPDO COB-ID dec TPDO COB-ID hex

1

385

181

2

386

182

3

387

183

4

388

184

5

389

185

6

390

186

7

391

187

8

392

188

9

393

189

10

394

18A

11

395

18B

12

396

18C

13

397

18D

14

398

18E

15

399

18F

16

400

190

17

401

191

18

402

192

19

403

193

20

404

194

21

405

195

22

406

196

23

407

197

24

408

198

25

409

199

26

410

19A

27

411

19B

28

412

19C

29

413

19D

30

414

19E

31

415

19F

32

416

1A0

33

417

1A1

34

418

1A2

35

419

1A3

36

420

1A4

37

421

1A5

38

422

1A6

39

423

1A7

40

424

1A8

41

425

1A9

42

426

1AA

43

427

1AB

44

428

1AC

45

429

1AD

46

430

1AE

47

431

1AF

48

432

1B0

Data Protocol of the Transmit PDOs

The Data Protocol of the Transmit PDOs must be set according to the Woodward CANopen device used. The following tables shows the supported Data Protocols.

Table 5. Supported Data Protocols
Woodward CAN device Data protocol Mapped Object ID TPDO COB-ID range dec (hex)

Easygen-3000 series

5003

n/a

385 (0x181) - 400 (0x190)

LS-5

5103

n/a

385 (0x181) - 400 (0x190)

Easygen-1000 series

4000 or 4003

n/a

385 (0x181) - 400 (0x190)

Easygen-2000 series

5100 or 5101

n/a

385 (0x181) - 400 (0x190)

DTSC-200

4700 or 4701

03190

385 (0x181) - 400 (0x190)

Specific information for Easygen-3000 series controls

The most convenient way to configure the Easygen is using Woodward’s Toolkit software. Below are Toolkit screenshots of the relevant menus.

Configure interfaces
Figure 20. "Configure interfaces" menu in Woodward Toolkit

CAN interface

From Woodward’s Toolkit software select the Configure CAN interface 1 page as shown below:

Configure CAN interface 1
Figure 21. "Configure CAN interface 1" menu in Woodward Toolkit
  • Parameter 3156 Baudrate must be set to 250 kBd.

  • Parameter 8950 Node-ID should match the device ID. It must be in the range of 1 to 127 and a unique number in the network.

Transmit PDOs

In order for the ESEPRO gateway to receive cyclic data updates from the Easygen, one of the five available Transmit PDOs (TPDO) must be configured. Typically Tranmsit PDO 1 is already pre-configured for that purpose, but any of the five TPDOs could be used for that purpose.

If for example Transmit PDO 1 is used, then:

  • parameter 9600 COB-ID must be set to 384 + Node-ID,

  • parameter 8962 Selected Data Protocol to 5003 and

  • parameter 9602 Tramsission type to 255.

In the following example for an Easygen with device ID of 1 and Node-ID of 1, the Transmit PDO 1 is used to send data updates every 20 ms:

Transmit PDOs
Figure 22. "Transmit PDOs" menu in Woodward Toolkit
Important All COB-IDs used in the CAN network must be unique. Please make sure that a COB-ID is only configured once. If TPDO or RPDO COB-ID entries are referring to an already used COB-ID, either disable that PDO or change its COB-ID.

Specific information for LS-5 controls

The LS-5 CANopen parameters are configured using Woodward’s Toolkit software. Below are Toolkit screenshots of the relevant menus.

Interfaces config
Figure 23. "Interfaces config" menu in Woodward Toolkit

CAN interface

From Woodward’s Toolkit software select the CAN interface 1 config page as shown below:

CAN interface 1 config
Figure 24. "CAN interface 1 config" menu in Woodward Toolkit
  • Parameter 3156 Baudrate must be set to 250 kBd.

  • Parameter 8950 Node-ID should match the device ID. It must be in the range of 1 to 127 and a unique number in the network.

Transmit PDOs

In order for the ESEPRO gateway to receive cyclic data updates from the LS-5, one of the five available Transmit PDOs (TPDO) must be configured. Typically Tranmsit PDO 1 is already pre-configured for that purpose, but any of the five TPDOs could be used for that purpose.

Transmit PDOs
Figure 25. "Transmit PDOs" menu in Woodward Toolkit

If Transmit PDO 1 is used, then:

  • parameter 9600 COB-ID must be set to 384 + Node-ID,

  • parameter 8962 Selected Data Protocol to 5301 and

  • parameter 9602 Tramsission type to 255.

Important All COB-IDs used in the CAN network must be unique. Please make sure that a COB-ID is only configured once. If TPDO or RPDO COB-ID entries are referring to an already used COB-ID, either disable that PDO or change its COB-ID.

Decommissioning

Before disconnecting the ESEPRO unit please follow the rules in [Safety].

Disconnecting

icons/warning.png
  1. Ensure that the system power and external supplies have been turned off.

  2. Disconnect power supply plug.

  3. Disconnect all I/O cables.

  4. Remove the ESEPRO from the DIN rail following the procedure described in [removal].

Disposal

icons/AJ_Recycling_Symbol.png

This product must be disposed of at a specialized electronic waste recycling facility. Do not dispose of in domestic waste.

Appendix A: Specifications

Product name

ESEPRO

Interfaces

Profibus

1 DP-Slave

CAN

1

Ethernet

1 (diagnostics and firmware upgrade)

User interface

LED indicators

Power (green), Ethernet link (green), 2 status (bi-color red/green)

Monitoring

Web browser based

Diagnostic

High availability features

Watchdog supervision, brown-out detection

Profibus interface

Connector

female 9-pin D-sub, Profibus standard (IEC 61158-2) pin-out

Physical layer

EIA-485-A (RS-485)

Isolation

500 V galvanic

Speed

9.6 kBit/s - 12 MBit/s

Protocols

Profibus DP-V0 and DP-V1 Slave

Max. nodes on a single bus segment

32

CAN interface

Connector

male 9-pin D-sub, industry standard CiA DS-102 pin-out

Physical layer

ISO 11898

Isolation

non-isolated

Speed

250 kBit/s

Protocols

CANopen consumer & client

Max. nodes on a single bus segment

64

Number of adressable nodes

8

Ethernet port

Connector

8-pin RJ-45 socket for Cat 5 UTP

Physical & Data Link Layer Layer

IEEE 802.3i 10BASE-T

Isolation

1.5 kV galvanic

Speed

10 Mbit/s

Max. cable length

100 m (328 ft)

Ethernet frame types

802.3

Protocols

Toolkit, HTTP, IP, TCP, ARP

Concurrent connections

2 HTTP

Power supply

Connector

3.81 mm 2-pin pluggable terminal block header

Voltage

10-30 V DC

Current

30 mA typical @ 24 V DC

Intrinsic consumption

750 mW

Electromagnetic compatibility

Emissions (radiated and conducted)

AS/NZS CISPR 22 / EN 55022 (Class A)

Immunity

EN 55024

Electrostatic discharge

EN 61000-4-2

Radiated RF

EN 61000-4-3

Fast transients

EN 61000-4-4

Conducted RF

EN 61000-4-6

Enclosure

Material

Self-extinguishing PC/ABS blend (UL 94-V0)

Mounting

35 mm DIN rail (EN 60715)

Classification / Type rating

IP 20 / NEMA Type 1

Cooling

Convection

Environmental

Operating temperature

0 to 60 °C / 32 to 140 °F

Storage temperature

-25 to 85 °C / -13 to 185 °F

Humidity

10 to 95% non condensing

Operating ambience

Free from corrosive gas, minimal dust

Physical

Dimensions

101 x 22.5 x 120 mm / 3.98 x 0.886 x 4.72 in

Weight

0.15 kg / 0.33lb

Compliance

Australia

C-Tick

Europe

CE, RoHS

USA

FCC Part 15 (Class A)

Canada

ICES-003 (Class A)

Dimensions

Dimension Drawing
Figure 26. Enclosure dimensions

References

  • [PIG98] PROFIBUS Nutzerorganisation e.V., "Installation Guideline for PROFIBUS-DP/FMS", Order No 2.112, Version 1.0, September 1998

Glossary

10BASE-T

10 Mbit/s twisted pair Ethernet standard. Standardized in IEEE 802.3i

APIPA

Automatic Private IP Addressing

CAN

Controller area network. Standardized in ISO 11898.

CANopen

Internationally standardized (EN 50325-4) CAN-based higher-layer protocol for embedded control systems.

CiA DS-102

Standard for the pinout of CAN connectors

Class A

Class A equipment is that used in commercial or light industrial environments.

COB-ID

Unique CANopen Communication Object Identifier.

DIN rail

35 mm wide mounting bracket standardized in DIN/EN 50022.

DP

Decentralised periphery. A Profibus protocol for the simple, fast, cyclic and deterministic I/O data exchange between a bus master and its assigned slave devices.

DP-V0

DP-V0 is the basic stage of the Profibus DP communication protocol providing cyclic data exchange.

DP-V1

Extension to Profibus DP protocol providing acyclic data transfer and alarms.

EMC

Electromagnetic compatibility

EMI

Electromagnetic interference

ESD

Electrostatic discharge. ESD can damage electronic equipment.

IEEE

Institute of Electrical and Electronics Engineers

IP

Ingress Protection Rating standardized in IEC 60529. Standard for various grades of electrical enclosures.

ISO

International Standards Organisation

MAC address

Every piece of Ethernet hardware has a unique number assigned to it called it’s MAC address. MAC addresses are administered and assigned by the IEEE organization.

MS1

Acyclic communication between a class 1 master and a slave device

MS2

Acyclic communication between a class 2 master and a slave device

Mux

Multiplexed process data object. Proprietary extension by Woodward to the CANopen protocol.

NEMA

National Electrical Manufacturers Association. NEMA defines standards for various grades of electrical enclosures.

Node

A communications device on the network

PC/ABS

Polycarbonate-ABS. Widely used thermoplastic material.

PDO

CANopen Process Data Object. Process data the device is either producing or consuming.

PLC

Programmable Logic Controller

Predefined Connection Set

The CANopen Predefined Connection Set defines standard COB-IDs for PDOs and SDOs.

Profibus

Fieldbus protocol used in the process automation industry. It uses a multiple master and slave structure with predictable cyclic communications. Originally developed by Siemens.

SDO

CANopen Service Data Object.

TPDO

CANopen Transmit Process Data Object. Process data the device is producing.

RPDO

CANopen Receive Process Data Object. Process data the device is consuming.

UL 94

Plastics flammability standard released by Underwriters Laboratories of the USA.


Document revision history

2014-01-22

Initial Release


No part of this material may be reproduced or transmitted in any form or by any means or used to make any derivative work without express written consent from the copyright holders.

proconX is a trademark of proconX Pty Ltd. PROFIBUS and PROFIBUS-DP are trademarks of PROFIBUS & PROFINET International (PI). CANopen is a registered trademark of CAN in Automation e.V. Easygen is a trademark of Woodward, Inc. All other product and brand names mentioned in this document may be trademarks or registered trademarks of their respective owners.

Disclaimer

proconX Pty Ltd makes no warranty for the use of its products, other than those expressly contained in the Company’s standard warranty which is detailed in the Terms and Conditions located on the Company’s Website. The Company assumes no responsibility for any errors which may appear in this document, reserves the right to change devices or specifications detailed herein at any time without notice, and does not make any commitment to update the information contained herein. No licenses to patents or other intellectual property of proconX are granted by the Company in connection with the sale of proconX products, expressly or by implication. proconX products are not authorized for use as critical components in life support devices or systems.

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Contact

For further information about the ESEPRO product or this document please contact us at:

proconX Pty Ltd
Unit 7 / 14 Argon St
Sumner QLD 4074
Australia
Tel +61 7 3376 3911
Website: http://www.proconx.com/esepro

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