Profibus

2 ｜Sinergia_Engineering – [Hardware plan]

Topics
• Profibus Presentation

• Characteristics

• Bus Distribution

• Profibus Components, Addressing

• Bus Termination

• Malfunctions and Diagnoses

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Profibus Presentation
PROFIBUS (=Process Field Bus)

Initiated in 1987 as a joint project of the German industry

Standards: DIN 19245 part 1, 2, 3

IEC 1158-2 (intrinsically safe bus physics)
EN 50170 (international since 1996)

Three variants:

DP decentralised periphery (fast cyclic data transmission

FMS Fieldbus Message Specification (universal communication tasks)

PA Process automation (process technology, for intrinsically safe area)

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Profibus Presentation
Reasons for Profibus Application in Bottling plants Technology:

• High data security

Use of "twisted pair" or fibre-optic cables

• Flexibility
One system with interfaces for different demands
Optimum adjustment of the network topology
possible
Transmission over long distances

• Standardised and open network

Large selection of components and systems on the
market
Manufacturer-independent network
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General Network Hierarchies

Ethernet (TCP/IP)
Control
level
LDS
Profibus FMS or Daten-Server
Ethernet (TCP/IP)

Cell level
B&R
Touch X20
Profibus DP

Field level
ASI
Drives
Drives
Master
DP/DP
Coupler

Actuator/
Sensor level
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Characteristics
• Transmission physics RS 485 (symmetrical data transmission, multi-point
compatible)

• Transmission rate 9.6 kBit/s - 12 MBit/s

(krones standard: 1.5 MBit/s)

• Transmission medium Electrical: shielded and twisted two-wire cable

Optical: fibre-optic cables (glass and plastic)

• Max. number of stations 127 (32 stations per segment)

(krones: max. 96 stations)

• Network size Electrical: max. 9.6 km (depending on data rate)

Optical: more than 100 km (depending on data rate)

• Topology Line
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Kenndaten
RS 485 Transmission Physics

Differential mode voltage A – B (approx. 5V)

→ potential A higher than potential B (log. 0)
→ potential B higher than potential A (log. 1)

+12 V

-7 V Bus line

A B
Transmitter Receiver
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Characteristics
Symmetrical data transmission according to EIA RS485 standard

+5V +5V

390Ω

Differential
220Ω 1 0 1 1 0 1
mode voltage
approx. 5V

390Ω
2 3 127

Master/PLC
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Bus Distribution

Connection diagram, assembly 0501

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Bus Distribution
Segments and Repeaters

- Stub Segment 1

RS 485-
Repeater
Segment 2
RS 485-
Repeater

Segment 3

A bus section comprises max. 32 stations and is called "segment“

At the end, a repeater must be inserted.
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Profibus Components, Addressing

Addressing of the Profibus stations

The Profibus stations are addressed:

1. In the hardware configuration of the S7 software
2. At the unit itself via DIP switches (binary code) or rotary switches
with units and ten digits

The Profibus address and the position of the DIP switches is shown on the component
in the hardware wiring diagram.
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Profibus Components, Addressing

Hardwareconfiguration S7/PLC

DP/DP- Koppler
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Profibus Components, Addressing

PLC S7
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Profibus Components, Addressing

AS-i Master
Adressing in the main menu
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Profibus Components, Addressing

Danfoss frequency inverter
Adressing
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Profibus Components, Addressing

DP/DP Coupler

Adressing
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Profibus Components, Addressing

Signal exchange via Profibus
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Profibus Components, Addressing

Repeater

Terminating resistor
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Bus Termination
Bus Connector

Each line (Segment) must be terminated at the first and last node with a terminating resistor (220 Ω ),
in order to avoid interfering reflections.

Terminating resistor

390 Ω
switch
220 Ω
390 Ω

Pin 5 Pin 6 Pin 8 Pin 3

(GND) (+5V) (A) (B)
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Bus Termination
Bus Connector/ Tool

connector design

Stripper for Profibus cable

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Bus Termination/ Signal processings

Bus terminated at both ends Bus terminated at one end

Bus without terminating resistor Bus with three switched terminating resistors
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Malfunctions and Diagnostics

Possible Profibus network malfunctions:

• Address was not set or was set incorrectly.

• The terminating resistor was not set as shown

in the diagram.

• Broken cable

• The cores in Profibus plugs A (green) and B

(red) were switched.

• The Profibus cable was put together with the

motor cable.
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Malfunctions and Diagnostics

Fault indication on the touchscreen
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Malfunctions and Diagnostics

Diagnostic on the touchscreen
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Malfunctions and Diagnostics

Profibus testing tool

The signal of the noise ratio can be checked by using special testing tools (e.g., Profibus tester PBT3).
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Malfunctions and Diagnostics

Profibus testing tool
Questions?