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OPC to Profibus Gateway

Installation Manual v1.0 (Release)

Telephone: +27 (11) 548 9960 or +27 (11) 465 7916 Fax: +27 (11) 465 8890 Email: info@idxonline.com Web: www.idxonline.com

OPC to Profibus Installation Manual

Discipline:

Industrial IT

Prepared By
Name
Jonathan Temlett (JT)

Project/Organisation Role
Solution Developer

Contact
jonathant@idxonline.com

Version Control
Version
v0.1 v1.0

Status
Draft Release

Date
2011-01-24 2011-01-25

Author JT MG

Change Description First draft Grammatical corrections.

Approved By
Name Project / Organisation Role Version Approved Date

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Table of Contents

1.

Installation .................................................................................................................................1 1.1 Physical installation....................................................................................................................... 1 Device clearance ................................................................................................................... 1 Mounting positions ............................................................................................................... 2

1.1.1 1.1.2 1.2

Network installation...................................................................................................................... 3 Network Cable....................................................................................................................... 3 IP addresses .......................................................................................................................... 4 Network Configuration ......................................................................................................... 4

1.2.1 1.2.2 1.2.3 1.3 2.

Power ............................................................................................................................................ 7

Configuration .............................................................................................................................9 2.1 2.2 Remote Desktop ........................................................................................................................... 9 Software configuration ................................................................................................................. 9 OPC Server (Kentima software) ............................................................................................ 9 IDX Software ......................................................................................................................... 9

2.2.1 2.2.2 2.3 2.4 2.5

Profibus configuration .................................................................................................................. 9 OPC configuration ....................................................................................................................... 10 Data mapping .............................................................................................................................. 10

Appendix A Profibus Mapping .........................................................................................................1 Appendix B OPC Tags.......................................................................................................................1

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Table of Figures

Figure 1 - Device dimensions ........................................................................................................................ 1 Figure 2 - Device bracket layout ................................................................................................................... 2 Figure 3 - Network cable pin allocation diagram using M12 D-coded connector ........................................ 3 Figure 4 - Network cable pin allocation diagram using M12 A-coded connector ........................................ 4 Figure 5 - Network Connection window ....................................................................................................... 5 Figure 6 - Sandvik ASRi Network Properties ................................................................................................. 6 Figure 7 - Network card Advanced options .................................................................................................. 7 Figure 8 - Power pin allocation ..................................................................................................................... 8

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1.
1.1

Installation
Physical installation

When installing the IDX Brick, you need to take into account the clearance needed for cables and the device itself. Please refer to the images provided for details regarding the size of the device. 1.1.1 Device clearance The IDX Brick is really simple to install. It has a set of brackets that allow you to mount it onto a suitable surface. Below are the dimensions of the device to indicate the clearance it requires. The dimensions are in cm.

Figure 1 - Device dimensions

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1.1.2 Mounting positions Below is the schematic for the mounting positions of the brackets. The dimensions are in cm.

Figure 2 - Device bracket layout

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1.2

Network installation

The communication between the ASRi panel and the IDX gateway is an integral part of the solution. You therefore have to insure that the network is setup and configured correctly. 1.2.1 Network Cable The ASRi panel has a D-coded M12 female connector exposed on the outside of the panel. It is possible however to use a M12 connector with the A-coding to connect to the ASRi. Please ensure you follow the instructions based on the connector type you use. To create a network connection you will need a cable that has a D-coded (or A-coded) M12 male connector on one end, and a RJ45 (standard Ethernet plug) on the other end. Below are the pin allocations for the cable to create a cross-over cable that will allow the ASRi panel to be connected directly to the IDX Brick.

Figure 3 - Network cable pin allocation diagram using M12 D-coded connector

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Figure 4 - Network cable pin allocation diagram using M12 A-coded connector

1.2.2 IP addresses The ASRi panel has its IP address set to a default IP Address = 10.0.0.2 Sub Net Mask = 255.255.255.0 The IDX Brick has its IP address set to a default IP Address = 10.0.0.1 Sub Net Mask = 255.255.255.0 If one of the specified IP addresses is changed, please ensure that the other IP is changed accordingly. Subnet masks must match. If changing the address of the IDX Brick is required, you will have to Remote Desktop into the device to apply new addresses. Please refer to section 2.1 Remote Desktop for more details. 1.2.3 Network Configuration Once the cable has been made and the IP addresses set, we have to configure the network card for the type of connection it must expect. Connect to the ASRi via Remote Desktop and open the Network Connections Page. You should see the window below. Follow the instructions in the next 3 figures:

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Figure 5 - Network Connection window

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Figure 6 - Sandvik ASRi Network Properties

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Figure 7 - Network card Advanced options

The above process will configure the IDX Brick so that the network card knows what to expect from the ASRi touch panel. To ensure there is a connection, open command prompt and ping the touch panel.

1.3

Power

The IDX Brick is able to handle a voltage range of 9-36 volts (DC). Please ensure that the voltage supplied is within this range, otherwise the IDX Brick will be damaged. Below are the power pin allocations.

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Figure 8 - Power pin allocation

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2.

Configuration

The IDX Brick has been preconfigured to a generic configuration. If you want to customise the configuration to suit your specifications, please follow the explanations regarding the topic of interest. In all cases you will have to create a Remote Desktop session to access the configuration utilities for the IDX Brick.

2.1

Remote Desktop

Remote Desktop is a built-in Windows feature. To create a remote desktop session, connect to the address of the IDX Brick with the following details: Username: Password: Administrator [enabled]

If you are unfamiliar with the concept of Remote Desktop, it is advised that you search for the topic as there are many articles on the internet explaining the concept. Otherwise you are free to contact IDX for advice on the topic and also for the password.

2.2

Software configuration

2.2.1 OPC Server (Kentima software) The IDX Brick has the Kentima software installed so that it can expose the data received from the ASRi panel as OPC tags. It is configured by default to connect to IP: 10.0.0.2 on port: 2123 with the name Crusher1. This influences that OPC tags names, so do not change the name unless you have been advised by IDX. The server is installed in C:\Program Files\Kentima\ 2.2.2 IDX Software The IDX software installed on the IDX Brick serves as the main control system for the OPC-to-Profibus device. It is preconfigured to map the required ASRi tags into the Profibus driver. If there is a custom configuration required, please refer to the specific configuration section, or contact IDX for specific instructions.

2.3

Profibus configuration

The Profibus driver on the IDX Brick exposes both Cyclic and Acyclic data. The OPC tags which are important to the control process have been packaged into the Cyclic memory area. If there is any need for Acyclic data, please contact IDX for details on how to expose the data. The IDX Brick contains a wizard for the customization of the Profibus settings. The default mapping can be found in Appendix A. The default Profibus settings are: Profibus Address : Input IO Size : Output IO Size : 10 244 84

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It is not advised to change any of the other Profibus settings. The only property you should need to change is the Profibus address. This can be done by running the configuration wizard. To run the wizard, please install the wizard software.

2.4

OPC configuration

The IDX Brick contains a wizard for the customization of the OPC tags which are captured in the software. The default OPC tags which have been exposed can be found in Appendix B.

2.5

Data mapping

The IDX Brick maps the information exposed on the OPC server as data packaged into the Profibus message. Please refer to the Appendix A for information on the mapping.

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Appendix A Profibus Mapping


Below is the list of memory addresses to which the specified OPC tags have been configured. TagName A.Alarm_A01 A.Alarm_A02 A.Alarm_A03 A.Alarm_A04 A.Alarm_A05 Acal ActiveUnackedAorBAlarm ADimLinerChange AI_OilTemp AI_Position AI_Power AI_Pressure AlarmLubricationOilTemp AutoCompFactorAvg AvgAPosLoad B.Alarm_B10 B.Alarm_B11 B.Alarm_B12 B.Alarm_B14 B.Alarm_B15 B.Alarm_B16 B.Alarm_B17 B.Alarm_B18 B.Alarm_B19 B.Alarm_B20 B.Alarm_B21 B.Alarm_B22 B.Alarm_B23 B.Alarm_B24 C.Alarm_C21 C.Alarm_C23 C.Alarm_C24 C.Alarm_C27 C.Alarm_C28 C.Alarm_C29 C.Alarm_C30 Data Type Bit Bit Bit Bit Bit Float Bit Float Float Float Float Float Float Float Float Byte Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit Address 134.0 134.1 134.2 134.3 134.4 168 134.5 10 160 164 22 26 30 34 38 136.0 136.1 136.2 136.3 136.4 136.5 136.6 136.7 137.0 137.1 137.2 137.3 137.4 137.5 137.6 138.0 138.1 138.2 138.3 138.4 138.5

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C.Alarm_C31 C.Alarm_C32 CalState CrusherLoaded CrusherType CrushingProgramError CSS CurrentMaxPower CurrentRunMode DI_MotorProtector DI_PumpDown DI_PumpUp DO_Alarm DO_Feeder DO_PumpDown DO_PumpUp HeartBeat_Integer IdlePower MaxA MaxMotorPower MaxPower MinA PageRequest PowerAvg Pressure MeterMax PumpDown PumpUp StartCrushingProgram Stat_CssAvgLast30Min Stat_CssMaxLast30Min Stat_CssMinLast30Min Stat_EnergyConsumptionSinceMantleChange Stat_PowerAvgLast30Min Stat_PowerMaxLast30Min Stat_RemainingShaftTravel Stat_TimeSinceCalibrationLoad Stat_TimeSinceLinersChangeLoad TrafficLight_GreenOn TrafficLight_RedOn TrafficLight_YellowOn

Bit Bit Word Bit String(10) Bit Float Float Word Bit Bit Bit Bit Bit Bit Bit Float Float Float Float Float Float Word Float Float Bit Bit Word Float Float Float Float Float Float Float Float Float Bit Bit Bit

138.6 138.7 42 139.0 140 139.1 46 50 54 150.0 150.1 150.2 150.3 150.4 150.5 150.6 16 58 62 66 70 74 0 78 82 2.0 2.1 4 86 90 94 98 102 106 110 114 118 151.0 151.1 151.2

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Appendix B OPC Tags


Below is the list of OPC tags which have been configured in the IDX Brick. OPC Tag Crusher1.DI.DI_MotorProtector Crusher1.DI.DI_PumpDown Crusher1.DI.DI_PumpUp Crusher1.DO.DO_Alarm Crusher1.DO.DO_Feeder Crusher1.DO.DO_PumpDown Crusher1.DO.DO_PumpUp Crusher1.Boolean.PumpDown Crusher1.Boolean.PumpUp Crusher1.AI.AI_Position Crusher1.Double.CSS Crusher1.Double.Acal Crusher1.Double.AvgAPosLoad Crusher1.Double.MaxA Crusher1.Double.MinA Crusher1.Double.AutoCompFactorAvg Crusher1.Double.ADimLinerChange Crusher1.AI.AI_Power Crusher1.Double.PowerAvg Crusher1.Integer.CurrentMaxPower Description ON = Motor protector circuit is tripped ON = Main shaft is pumping down ON = Main shaft is pumping up ON = The ASRi has an active alarm(s) ON = The ASRi permits the feeder to be on ON = The ASRi wants to pump the main shaft downwards ON = The ASRi wants to pump the main shaft upwards ON = Pump the main shaft downwards manually ON = Pump the main shaft upwards manually Current A-dimension Current CSS The calculated A_dimension for the current metal-to metal position Average A-dimension at which the crusher has run loaded for the last four minutes Maximum A-dimension Minimum A-dimenison Current wear compensation factor A-dimension limit for alarm C27 (Parameter 503) Current Power Current average power, 0 - 1000 The crushers max power according to the selected crushing program, 0 - 10000

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Crusher1.Integer.MaxMotorPower Crusher1.Integer.MaxPower Crusher1.Integer.IdlePower Crusher1.AI.AI_OilTemp Crusher1.AI.AI_Pressure Crusher1.Double.Pressure MeterMax Crusher1.Integer.CurrentRunMode Crusher1.Integer.StartCrushingProgram Crusher1.Boolean.CrushingProgramError Crusher1..CurrentCrusherProg Crusher1.Boolean.CrusherLoaded Crusher1.String.CrusherType Crusher1.Integer.CalState Crusher1.Integer.HeartBeat_Integer Crusher1.Integer.TrafficLight_GreenOn Crusher1.Integer.TrafficLight_RedOn Crusher1.Integer.TrafficLight_YellowOn Crusher1.Boolean.ActiveUnackedAorBAlarm Crusher1.Double.AlarmLubricationOilTemp Crusher1.Alarm.A.Alarm_A01 Crusher1.Alarm.A.Alarm_A02 Crusher1.Alarm.A.Alarm_A03 Crusher1.Alarm.A.Alarm_A04 Crusher1.Alarm.A.Alarm_A05 Crusher1.Alarm.B.Alarm_B10 Crusher1.Alarm.B.Alarm_B11

Max permissible continuous power output from the motor, 0 1000 (parameter 502) The crushers max input power 0 - 1000 (parameter 601) Power when the crusher is considered idle Current return oil temperature, 0 - 200 Current pressure, 0 - 25 100% allowed pressure load The crushers current run mode. 1 = Stop, 2 = Manual, 3 = Auto, 4 = Calibration Sets the current running mode of the crusher. 1 = Stop, 2 = Manual, 3 = Auto True = Error in selected crushing program The currently selected crushing program True = The crusher is considered to be loaded Name of the crusher Type State during calibration (0-11) Heart beat value that increments 1 with every program loop 1 = The green light of the traffic light is lit 1 = The red light of the traffic light is lit 1 = The yellow light of the traffic light is lit True if there is an active unacknowledged A or B alarm. Causes the status row to blink Temperature limit for alarm B15 (parameter 507) A01 No pressure signal A02 No A-dimension signal A03 Power signal too high A04 Pressure signal too high A05 A-dimension signal too high B10 Oil temperature signal too high B11 No power signal

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Crusher1.Alarm.B.Alarm_B12 Crusher1.Alarm.B.Alarm_B14 Crusher1.Alarm.B.Alarm_B15 Crusher1.Alarm.B.Alarm_B16 Crusher1.Alarm.B.Alarm_B17 Crusher1.Alarm.B.Alarm_B18 Crusher1.Alarm.B.Alarm_B19 Crusher1.Alarm.B.Alarm_B20 Crusher1.Alarm.B.Alarm_B21 Crusher1.Alarm.B.Alarm_B22 Crusher1.Alarm.B.Alarm_B23 Crusher1.Alarm.B.Alarm_B24 Crusher1.Alarm.C.Alarm_C21 Crusher1.Alarm.C.Alarm_C23 Crusher1.Alarm.C.Alarm_C24 Crusher1.Alarm.C.Alarm_C27 Crusher1.Alarm.C.Alarm_C28 Crusher1.Alarm.C.Alarm_C29 Crusher1.Alarm.C.Alarm_C30 Crusher1.Alarm.C.Alarm_C31 Crusher1.Alarm.C.Alarm_C32

B12 Shaft at bottom posiont under load B14 Hydroset pump motor protector tripped B15 Return oil too hot B16 'Pump up' response time too long B17 'Pump down' response time too long B18 'Pump up' command too long B19 'Pump down' command too long B20 No communication with power measurement unit B21 No communication with tank measurement unit B22 No communication with hydroset drive unit B23 Power to low compared to pressure B24 Pressure too low compared to power C21 No return oil temperature signal C23 Mainshaft at bottom position C24 Mainshaft at top position C27 Liner change necessary C28 Calibration needed C29 Axel does not move up C30 Axel does not move down C31 Axel moves up too slowly C32 Axel moves down too slowly

Crusher1.Double.Stat_CssAvgLast30Min Crusher1.Double.Stat_CssMaxLast30Min Crusher1.Double.Stat_CssMinLast30Min Crusher1.Double.Stat_PowerAvgLast30Min Crusher1.Double.Stat_PowerMaxLast30Min Crusher1.Double.Stat_RemainingShaftTravel

Average CSS for the latest 30 minutes Max CSS for the latest 30 minutes Min Css for the latest 30 minutes Average power for the latest 30 minutes Max Power for the latest 30 minutes Remaining shaft travel at current CSS

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Crusher1.Double.Stat_TimeSinceCalibrationLoad Crusher1.Double.Stat_TimeSinceLinersChangeLoad Crusher1.Double.Stat_EnergyConsumptionSinceMantleChange

The total time that the crusher has been loaded since the last calibration The total time that the crusher has been loaded since the liners where changed The total energy consumption since the last mantle change

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