No, it's possible to de-activate the use of the bus coupler diagnostic module.

The bus coupler diagnostic module is used to send/receive "internal" data's of the Bus coupler.
Whith the internal data's it's possible that the Profibus-DP master know the status of the bus-coupler and the DP Master can define the behaviour of the bus-coupler.
The internal data's use 4 Byte input and 4 Byte output on the Profibus-DP.

Per default it's mandatory to define as first module this bus coupler diagnostic module in the Profibus-DP configurator.
If needed it's possible to de-activate the bus coupler diagnostic module with the Service function 5 "Switch bus coupler diagnosis on/off".
If deactivated then it's forbiden to define the bus coupler diagnostic module in the Profibus-DP configurator.

When the 4 channels analog carte PCD2.W745 is used on a PCD3.T760 RIO module 6 registers are available on the master station. It is important to know that the 2 first registers contain the diagnostic bits of the 4 inputs channels!

How to interpret those 2 diagnostic registers (anal_16 and anal_17) ?
The first 2 bytes (low bytes) gives the diagnostic bit of 2 analog channels (1 byte per channel) as indicated in the following screenshot:


Signification of each bit (from right to left):

In some cases it is possible that a PCD7.F7500 is not correctly detected on a PCD2.M5540 with hardware version 'C' without modification '6'.

Symptom
The Profibus Master module PCD7.F7500 does not work while commissioning. During start-up of the PCD the Error LED is lit and in the history the message "PROF DP FAIL 000" is added (see screenshot from a diagnostic file below):

Reason
In some specific cases the PCD2.M5540 does not detect the PCD7.F7500. As result, the module can not be configured and the Error LED of the PCD is lit.
The PCD2.M5540 hardware version C with modification 3,5,6 contains a modification of the CPLD which assures that the module PCD7.F7500 it detected correctly.

Solution
Please use the PCD7.F7500 module with a PCD2.M5540 with the hardware version/modification "C 3,5,6"or newer.

In case you are concerned by this case and your PCD has an older version (e.g. version/modifications "C 3,4,5"), you need to replace the PCD2.M5540 with a newer one.

Remarks

• If the PCD2.M5540 is running with a PCD7.F7500 there is no need updating the hardware, even if the modification above is not applied (because the problem does only occur on some combinations of CPU and F-module
• Since May 2011 the PCD2.M5540 delivered by Saia-Burgess Controls AG have the modification 6 or later applied.

The maximum of exchanged data over a Profibus DP interface (or Profi-S-I/O) interface is depending on the system (the amount is not the same for a PCD7.F750 or a PCD3).

PCD7.F750 placed on a PCD2.M1x0 (non SBC-NT)
The Profibus DP manual states that the maximal amount of exchanged data per PCD7.F750 is 2942 bytes.

PCD3, PCD2.M5 or PCD2.M480 and PCD1.M2 (SBC-NT)
The limitation mentioned above does not apply for SBC-NT systems where the maximal amount of exchanged data is 2048 bytes.

When configuring a W525 module using the Device Configurator or the Profi-S-I/O (or Profibus DP) Network Configurator, the PCD2/3.W525 does need two registers for the analogue outputs and 8 registers for the analogue inputs.

The significations of the registers are the following:

Output registers: 

Description of the output registers:

Value CH0..1 (Register n, n+1)
This registers (Bit 0 to 15) does contain the analogue output value of the corresponding analogue output. It's a 12 Bit value.

Input registers:

Description of the input registers:

Value CH0..CH3 (Register n...n+3)
This registers (Bit 0 to 15) does contain the analogue input value of the corresponding analogue input. It's a 14 Bit value.

Load_Current / Load_Voltage (Register n+4)
On this register (Bit 0 to 15) the actual current or voltage value is displayed.

• current in [μA] (0..20'000)
• voltage in [mV] (0..10'000) 

Status Module (Register n+5)
This register (Bit 0 to 15) does contain the actual status of the module

Table module status:

Status Input (Register n+6)
This register (Bit 0 to 15) does contains the status of the input channels CH0..CH3.
The status of each input channel is displayed on 4 bits.

Table input status:

Status Output (Register n+7)
This register (Bit 0 to 15) does contain the status of the two output channels CH0 and CH1.
The status of each output channel is displayed on 6 bits.

Table output status:

On our Profibus DP Master modules and CPUs there are two LEDs available:

RUN = Yellow

ERROR = Red

Modules and CPUs
The LEDs RUN=Yellow and ERROR= Red are present on the following modules:
PCD7.F750
PCD7.F7500
PCD3.M654x: On this CPU the LEDs are below the cover. Otherwise you can see them if you open the blue cover that covers the battery-module, M1-, M2-Slot and the RUN Stop/switch. Through the little gap where the cover is cliped in, the LEDs are visible:



Status of the LEDs:
ERROR LED:
The ERROR LED is switched on for approximately 1 sec during startup. If the module is working correctly the error LED is switched of afterwards. In case the error LED is switched on or blinking the Profibus DP module has a serious problem that is most probably related to the hardware itself.

RUN LED:
The RUN LED is normally blinking after startup. If it is blinking fast (~10Hz), the Profibus communication is not running correctly. In case the Profibus communication works well, the RUN LED is blinking slowly (~1Hz). If the communication is not working properly, more information is available in the history of the PCD. Check the history of the PCD for Profibus DP FAIL errors (see list below for the meaning of these messages). If there is no entry in the history regarding the DP functionality, you can check the diagnostic flags and diagnostic registers. More information about the Profibus diagnostic is available in the manual Profibus DP 26/765. The manual is at the moment not up to date. Only the PCD7.F750 is mentioned. Otherwise most of the information in this manual like diagnostic information is valid for the PCD3.M654x and PCD7.F7500 as well. We are working on a new version.

PROF DP FAIL xxx (or PROF S-I/O fail if Profi-S-I/O is used)
ERR# Description
0 Key word MODE: not found
0 Wrong mode specified
0 Key word CONF: not found
0 DBX key word not specified
0 DBX number error
0 DBX number to large
0 DBX does not exist
0 Key word DIAG: not found
0 Flag or output key word not specified in DIAG
0 Error in address of diag flag or output
0 Range error diag flag or output
0 Register key word not specified in DIAG
0 Range error diag register
1 PROFIBUS-DP HW card not present
2 Error in instruction
3 DBX structure error
4 DBX type not for DP master (no PROFIBUS DBX)
5 FW-DBX version not compatible
6 No IN RING message after timeout on initialization
7 Semaphore error for data exchange (info to PCD support)
8 DBX error: data transfer function not implemented
9 Incompatible PCD7.F750 and PCD hardware

The Profibus DP-DP Coupler 6ES7 158-0AD00-0XA0 from Siemens is used to exchange data between two Profibus DP Master devices. The coupler itself acts as Profibus DP Slave and is to be connected to two different Profibus networks. It will copy the "input" of one side of the coupler to the "output" of the other side. This device is used by several customers and works with Profibus DP masters from SBC.

Important points when commissioning the 6ES7

• It is important that the modules on both sides of the DP/DP coupler do have an identical size
  When defining the modules, make sure that the size of the modules is identical on both "sides" (networks) of the coupler. Make sure that the "input" area of one side corresponds to the "output" area of the other side.
• The diagnostic bit in for the coupler has several possible meanings:
  - It can indicate "no communication"
  - or it can indicate a configuration mismatch (e.g. different size of the modules)
  - or it can indicate that no communication is running on the onter "side" of the coupler

The diagnostic flag Slave_Err does indicate that at least one Profibus slave has an error.

The error could be that the slave(s) is/are not connected to the Profibus network or that the slave(s) is/are connected to the Profibus network but do have diagnostic information’s.

That means that it's possible that a DP or Profi-S-IO Slave does communicate correctly but the diagnostic flag SLAVE_ERR and the corresponding bit on the diagnostic register Base+x is set to high because the slave does send a diagnostic information (for example overload on the output driver) to the master.

The concerned slave(s) number(s) is/are shown on the diagnostic register Base+3.. base+6.

To know the reason for the slave error on the application program it's necessary to perform a scon instruction # 1 "read slave diagnostic data" as described on the manual 26-765.

The configuration of the two devices has to match.

Problem
On the Saia side the DP configuration is made using the DP-network configurator and definig the modules to exchange. The CP 342-5 communicates using FC's.

Example
In the Siemens programming tool the FC 1 is used for sending data to the master. FC 2 is used for receiving data from the master. FC 3 and 4 can be used for diagnostic and control.
Example Siemens:
      CALL  FC     1
       CPLADDR:=W#16#100
       SEND   :=P#DB119.DBX0.0 BYTE 64
       DONE   :=M100.1
       ERROR  :=M100.2
       STATUS :=MW102

CPLADDR: Is the address of the CP 342-5 in hexadecimal (Decimal=256). This has to be defined in the Siemens Hardware Configuration.
SEND: Is the data to send. In this case the data is located in DB119. The amount of data to send is 64 Bytes.
DONE: Indicates if the function was executed
ERROR: Indicates errors
STATUS: Shows the actual status. For more information refer to the Simatic Manager help.

Example Saia:
On the Saia side we have to configure the same amount of BYTES. Since the Slave sends 64 BYTE the configuration on the SAIA site has to be 64 BYTES as well.
There are two possibilities:
32 word AI constcy complet: in this case the data is mapped to registers
or
64 bytes AI constcy complet: in this case the data is mapped to flags.

The same structur can be used if the Siemens Slave receives data from the master:

Example Siemens:
      CALL  "DP_RECV"
       CPLADDR :=W#16#100
       RECV    :=P#DB119.DBX100.0 BYTE 64
       NDR     :=M200.1
       ERROR   :=M200.2
       STATUS  :=MW202
       DPSTATUS:=MB204

Example Saia:
32 word AO constcy complet
or
64 bytes AO constcy complet

Description of a possible malfunction in relation with a DP/Belimo gateway (device S-HER-UN-DP-Belimo Gateway from the company A-M-Systeme)

Description of a possible malfunction in relation with a DP/Belimo gateway (device S-HER-UN-DP-Belimo Gateway from the company A-M-Systeme): 

• Profibus-DP network with a PCD as DP master and a DP/Belimo gateway as DP slave
• DP communication woks fine.
• After a download of the application program to the PCD or a restart cold of the PCD the DP/Belimo gateway does show an error message on his display "SPS stopped" and the Error LED of the DP/Belimo gateway is blinking.
  The DP/Belimo gateway is not able to receive and send DP messages.
• On the DP diagnostic of the PCD there is no indication that the DP slave does not work but it’s not possible to read/write information’s from/to the DP/Belimo gateway.
•  A power off/on of the DP/Belimo gateway or the PCD does solve the problem. 

The problem was on the FW of the DP/Belimo gateway and was fixed on the FW 1.24d of the DP/Belimo gateway.

FW versions < 1.24d could have this problem. 

To update the FW of the DP/Belimo gateway please contact your DP/Belimo gateway supplier.

On the master PCD the I/O mapping to Register 4096 until Register 16'383 for RIO-networks (Profibus DP or Profi-S-I/O) doesen't work on PCD3 and PCD2.M480 and PCD2.M5xx0 systems with firmware version 1.08.23.

Symptom
When using addresses between 4096 to 16383 on the maser PCD for reading/writing medias of Profibus-DP / Profi-S-I/O slaves, no values can be read from these slaves. The relevant registers are not updated by the Profibus or S-I/O task in this case.
This problem does only occur with firmware versions 1.08.xx until version 1.08.31; it is therefore even possible that a project correctly runs until the firmware of the Profi-S-I/O or Profibus DP master PCD has been updated. 

Reason
The reason for this behavior is an incorrect mapping on the Profibus-DP / Profi-S-I/O master done by the firmware of the CPU. This behaviour has been introduced in version 1.08.xx (pilot versions already in 1.07.xx) and is solved in version 1.08.34 and later.

Solution
Please update the firmware of your

• PCD3 to 1.10.16 or later
• PCD2.M5 to 1.10.16 or later
• PCD2.M480 to 1.08.53 or later

If this is not possible for some reason, only use adresses R 0 - R 4095 to map the modules. 

The S-Net Configurator distributed with PG5 until version PG5 1.4.130 does impose too strong limitations regarding the amount of modules in the configuration. As result the maximal size of exchanged data can not be reached.

Symptom
When trying to configure a Profibus DP or a Profi-S-I/O master station that will exchange more than 160 bytes in- and output data with Profibus DP slaves, the consistency error message
Slave 2 "Slave" :
        Error 601: Configuration too large. Try removing some modules.

appears. Therefore it is not possible configuring the maximal amount of exchanged data.

Reason
There S-Net Configurator does calculate the limits according a very old version of the module PCD7.F750. In this old version (a pilot version) of the module much less memory for the data exchange has been available.

Solution
This wrong calculation of the maximum exchanged data is (will be) corrected in PG5 SP1.4.140. In case you need to configure the network with PG5 SP1.4.130, please contact your local sales office and request an appropriate version of the S-Net configurator (SNet32.exe).

Additional note
The Profibus DP manual states that the maximal amount of exchanged data per PCD7.F750 is 2942 bytes. This limitation does not apply for Saia PCD® COSinus systems (PCD2.M480, PCD3, PCD2.M5xxx or PCD1.M2) where the maximal amount of exchanged data per Profibus DP Master is 2048 bytes.
Note that the maximal amount of exchanged data per Profibus DP Slave is 244 bytes.

To communicate with a Siemens Slave it is necessary to place the modules Kennung generell 1-3.

If you change the baudrate in a SNet the new parameters must be downloaded with "Download hardwaresettings".

Rebuild and download also all programs.

Yes they are and starting in PG5 1.4 these modules are included in the S-Net Configurator by default. When using PG5 1.3 an import of a recent version of the GSE (or GSD) file is necessary. The firmware of the PCD3.T760 must be V 1.019 or later.

Problem
In the S-Net Configurator of PG5 1.3 (DP or S-I/O) the modules PCD3.W800, PCD3.A810 and PCD3.A860 are not implemented.
 
Reason
The mentioned modules are not implemented because at the time PG5 1.3 has been released the modules have not been available.

Solution
Upgrade the firmware of the PCD3.T760 to V 1.019 or later and with right-mouse-click on the T760 device in the SIO-configurator 'Remove Device ...' , delete the actual GSE-file. Then, import the new GSE file into the S-Net Configurator. Note that the new GSE file has to be named exactly 'PCD3.T760'. If the name is different, the S-I/O configurator will not use the new version. Old projects will also work correctly with the new GSE file.

When measuring e.g. the temperature of a Pt1000 sensor with a W-module mounted on a PCD3.T760, the sensor type can be configured in the SBC Network Configurator. If this is done this way, negative temeratures are not interpreted correctly on the PCD. Instead of negative values, very high values around 65000 are shown.

Symptom
The temperature values read from the PCD3.T760 aren't negative but very high (around 65000). Positive values read are interpreted correctly. All modules that do offer the possibility of reading temperature values are affected (PCD3.W220, PCD3.W340, PCD3.W350, PCD3.W360, PCD3.W745).

Reason
The reason for this phenomenon is the fact that the values transmitted over Profibus DP or Profi-S-I/O are signed 16-bit values. These values are copied directly into the signed 32-bit registers of the PCD. Due to the lack of a transfer function that converts the negative values (and copies the sign bit from the 16th to the 32th bit), the negative 16-bit values aren't correctly interpreted when copied into a 32-bit register.

Solution

Firmware versions supporting the transfer function (systems not listed in this table do not support the transfer function mentioned):

On other systems than the ones listed above the following workarounds are possible:

• Reading the raw values from the W-modules (1:1) and then converting these values e.g. in Fupla by using the FBox "20-point-conversion". A table for this conversion accroding to the applied module and senser type can be requested from pcdsupport@saia-pcd.com
• Converting the read temperature values at the very beginning of the COB 0. Because the read values are copied to the PCD registers always right before the start of the execution of the COB 0, this will convert the values always just after the writing into registers. All following COBs created by the user will have the correct values read from the PCD3.T760. An example code for this method is attached to this FAQ. This file also contains guide how to introduce this function into an existing project.

No, the GSD-Files are different. They have a different identification. The PCD2.M170 needs the GSD-File PCD2_Slave (SAIAcd20.gsd), otherwise the PCD4.M170 needs the PCD4.M170_Slave (SAIAcd40.gsd)

On Profibus Network it is important to use the right cable and connector as the communication speed goes up to 12 Mbautes!

Those cable and connectors are used in Profibus DP, FMS, Profis S-Bus, Profi S-IO and MPI!

The serial ports of the PCD2.M480 does allow to communicate up to 115 kB/s.

The PCD2.M480 does support the following baudrates:

• For the ports 2,3  and 4,5 following combination of baud rates are not allowed on the same  PCD2.F5xx:
  19,2 kBaud and 38,4 kBaud
• On the port 1 it’s not possible to use the S-Bus party Master mode.
• Mode D is not supported.

The Profibus DP configurator of PG5 1.3 (older than SP1.3.120) does create configuration files that don't run on a PCD2.M110/120 equipped with FW 080 and older.

Symptom
The Profibus DP Module can't be initialised. The error LED is lit instead and "PROFIBUS FAIL 000" is entered in the History of the PCD. Profibus DB Master and Slave configurations are concerned.

Reason
The reason for this problem is that the Profibus DP configurator (coming along with PG5 1.3.100 or SP1.3.110) will store the configurations in DBX 4. This address isn't available in FW versions up to 080 (since only 4 DBX are available, address 0 included).

Solution

• Either update to the latest official FW for the PCD2

• Or Update to PG5 SP1.3.120 (or higher)

There are basically two tools that are required to solve communication issues on Profibus based networks (like Profi-S-Bus, Profi-S-IO, Profibus DP):

• an oscilloscope to locate hardware related problems (see related topics for more information)

• a protocol analyzer specialized for Profibus based networks

The protocol analyzer we recommend is ProfiTrace (www.profitrace.com) with the Oscilloscope Option. This analyzer bases on an up to date hardware and software concept and is easy to use. The oscilloscope option allows to observe telegrams of specific stations on the oscilloscope, ProfiTrace is generating the necessary trigger signals.

In Switzerland ProfiTrace is represented by  Berner Fachhochschule, Hochschule für Technik und Informatik, please refer to labs.hti.bfh.ch/index.php for more details.

If a DP slave has a bus interruption in the space of watchdog time, the master station (PCD7.F750)

doesen’t refresh automatically the diagnostic flags and registers.

In PG5 SP1.2.130 the analogue module PCD3.W745 isn't implemented. To be able to configure the PCD3.W745 on a PCD3.RIO the latest *.gsd file is required.

The corresponding *.gsd file is available on the Support Site under "Browse by product Code/PCD3/Txxx/Txxx".

Ad the new modules using the funtion "Ad device" of the menu "Library" of the SNet32.

Depending the PCD type there are up to 3 interfaces to connect the PCD to a Profibus DP or a Profi-S-I/O (or FDL in general) network.

Please consult the table below for the correct connection of the Profibus cables:

The Profibus network has to be terminated on both sides of it in one of the following ways:

1. Termination boxes that are placed at the begining and end of the line topologie (solution that should be preferd):

2. For baudrates up to 1.5 Mbaud the termination can also be realized directly on the first and last device of the network. Note that there are also specific connectors with housings with come with the resistors already equipped.

3. For higher baudrates the second solution is not suitable. Inductances has to be add to the termination:

Yes, it's possible.

During the import of the *.GSD or *.GSE file to the Profibus-DP configurator you can select in which groupe you want to store the new file.

You can select the existing groups or you can write a name in to the selection text. This will then create a new group on the device list of the Profibus-DP configurator.

Yes, it's possible.
During the import of the *.GSD or *.GSE file to the Profibus-DP configurator you can select in which groupe you want to store the new file.
You can select the existing groups or you can write a name in to the selection text. This will then create a new group on the device list of the Profibus-DP configurator.

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If GSD files are imported in to PG4/PG5 then this files are stored in a SBC specific format in the files dpdv.dat and dpsaiadv.dt.

If you want to use the imported GSD files on a other PC (with Saia PG5®) or on a other PG5 version then you have to copy the files dpdp.dat and dpsaiadv.dat from the old PC to the new PC

It's possible to add non SBC Profibus-DP devices to our PG4/PG5 Profibus-DP configurator. This *.GSD or *.GSE files can be added with the option "library, add device" to the device list of the Profibus-DP configurator.
During the import, the information of such *.GSD or *.GSE files are copied from the *.GSD/GSE files in to the SBC specific files dpdv.dat and dpsaiadv.dat which are located in the PG4/PG5 main folder.

If you like to use the stored *.GSD/GSD information on a other PC or on a newer version of PG5 then you have to copy this two files (dpdv.dat and dpsaiadv.dat) from the old PC to the new PC/PG5.

Note:
For PG4 and PG5 (The user himself has to save the files in to the backup project, and have to restore the files manually.

With PG5 V1.3 the files dpdv.dat and dpsaiadv.dat are saved together with the project during the backup of the project.
A restore of such projects will compare the content of the files dpdv.dat and dpsaiadv.dat stored on the PG5 main folder and the content of the saved dpdv.dat/dpsaiadv.dat and complete the files on the PG5 main folder with the additional information's stored on the saved files.

There are confusing screw terminal identifier terminologies around. Depending on the manufacturer the identifiers used are in conflict to the identifiers you can find in SBC manuals.

General
RS-485 is a Bus-system, therefore the signal wires shall not be crossed.

Sometimes "+Data" and "-Data" can be found on devices. Then "+Data" propably has to be connected to "/Rx-/Tx" (or /D) and "-Data" to "Rx-Tx" (or D).

Converters
Some products form other manufacturers (p.e. RS232 - RS485 converters) are often inversly indicated. Therefore it is sometimes necessary to cross the wires.

Profibus and Profi-S-I/O 

Example for the port 3 of the PCD3.M5540 as Serial-S-Bus
RS485 connection (Serial-S-Bus) between PCD3.M5540 port 3 (S-Net D-Sub used as RS485 Serial-S-Bus) and PCD2.M5540 port 2 (connector block X3):