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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: [email protected] Web: www.idxonline.com
OPC – to – Profibus Installation Manual
Version: Release v1.0 Page i 2011/01/25
Discipline: Industrial IT
Prepared By
Name Project/Organisation Role Contact
Jonathan Temlett (JT) Solution Developer [email protected]
Version Control
Version Status Date Author Change Description
v0.1 Draft 2011-01-24 JT First draft
v1.0 Release 2011-01-25 MG 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
1.1.1 Device clearance ................................................................................................................... 1
1.1.2 Mounting positions ............................................................................................................... 2
1.2 Network installation...................................................................................................................... 3
1.2.1 Network Cable ....................................................................................................................... 3
1.2.2 IP addresses .......................................................................................................................... 4
1.2.3 Network Configuration ......................................................................................................... 4
1.3 Power ............................................................................................................................................ 7
2. Configuration .............................................................................................................................9
2.1 Remote Desktop ........................................................................................................................... 9
2.2 Software configuration ................................................................................................................. 9
2.2.1 OPC Server (Kentima software) ............................................................................................ 9
2.2.2 IDX Software ......................................................................................................................... 9
2.3 Profibus configuration .................................................................................................................. 9
2.4 OPC configuration ....................................................................................................................... 10
2.5 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. Installation
1.1 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: Administrator
Password: [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 : 10
Input IO Size : 244
Output IO Size : 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 Data Type Address
A.Alarm_A01 Bit 134.0
A.Alarm_A02 Bit 134.1
A.Alarm_A03 Bit 134.2
A.Alarm_A04 Bit 134.3
A.Alarm_A05 Bit 134.4
Acal Float 168
ActiveUnackedAorBAlarm Bit 134.5
ADimLinerChange Float 10
AI_OilTemp Float 160
AI_Position Float 164
AI_Power Float 22
AI_Pressure Float 26
AlarmLubricationOilTemp Float 30
AutoCompFactorAvg Float 34
AvgAPosLoad Float 38
B.Alarm_B10 Byte 136.0
B.Alarm_B11 Bit 136.1
B.Alarm_B12 Bit 136.2
B.Alarm_B14 Bit 136.3
B.Alarm_B15 Bit 136.4
B.Alarm_B16 Bit 136.5
B.Alarm_B17 Bit 136.6
B.Alarm_B18 Bit 136.7
B.Alarm_B19 Bit 137.0
B.Alarm_B20 Bit 137.1
B.Alarm_B21 Bit 137.2
B.Alarm_B22 Bit 137.3
B.Alarm_B23 Bit 137.4
B.Alarm_B24 Bit 137.5
C.Alarm_C21 Bit 137.6
C.Alarm_C23 Bit 138.0
C.Alarm_C24 Bit 138.1
C.Alarm_C27 Bit 138.2
C.Alarm_C28 Bit 138.3
C.Alarm_C29 Bit 138.4
C.Alarm_C30 Bit 138.5
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C.Alarm_C31 Bit 138.6
C.Alarm_C32 Bit 138.7
CalState Word 42
CrusherLoaded Bit 139.0
CrusherType String(10) 140
CrushingProgramError Bit 139.1
CSS Float 46
CurrentMaxPower Float 50
CurrentRunMode Word 54
DI_MotorProtector Bit 150.0
DI_PumpDown Bit 150.1
DI_PumpUp Bit 150.2
DO_Alarm Bit 150.3
DO_Feeder Bit 150.4
DO_PumpDown Bit 150.5
DO_PumpUp Bit 150.6
HeartBeat_Integer Float 16
IdlePower Float 58
MaxA Float 62
MaxMotorPower Float 66
MaxPower Float 70
MinA Float 74
PageRequest Word 0
PowerAvg Float 78
Pressure MeterMax Float 82
PumpDown Bit 2.0
PumpUp Bit 2.1
StartCrushingProgram Word 4
Stat_CssAvgLast30Min Float 86
Stat_CssMaxLast30Min Float 90
Stat_CssMinLast30Min Float 94
Stat_EnergyConsumptionSinceMantleChange Float 98
Stat_PowerAvgLast30Min Float 102
Stat_PowerMaxLast30Min Float 106
Stat_RemainingShaftTravel Float 110
Stat_TimeSinceCalibrationLoad Float 114
Stat_TimeSinceLinersChangeLoad Float 118
TrafficLight_GreenOn Bit 151.0
TrafficLight_RedOn Bit 151.1
TrafficLight_YellowOn Bit 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 Description
Crusher1.DI.DI_MotorProtector ON = Motor protector circuit is tripped
Crusher1.DI.DI_PumpDown ON = Main shaft is pumping down
Crusher1.DI.DI_PumpUp ON = Main shaft is pumping up
Crusher1.DO.DO_Alarm ON = The ASRi has an active alarm(s)
Crusher1.DO.DO_Feeder ON = The ASRi permits the feeder to be on
Crusher1.DO.DO_PumpDown ON = The ASRi wants to pump the main shaft downwards
Crusher1.DO.DO_PumpUp ON = The ASRi wants to pump the main shaft upwards
Crusher1.Boolean.PumpDown ON = Pump the main shaft downwards manually
Crusher1.Boolean.PumpUp ON = Pump the main shaft upwards manually
Crusher1.AI.AI_Position Current A-dimension
Crusher1.Double.CSS Current CSS
Crusher1.Double.Acal The calculated A_dimension for the current metal-to metal position
Crusher1.Double.AvgAPosLoad Average A-dimension at which the crusher has run loaded for the last four minutes
Crusher1.Double.MaxA Maximum A-dimension
Crusher1.Double.MinA Minimum A-dimenison
Crusher1.Double.AutoCompFactorAvg Current wear compensation factor
Crusher1.Double.ADimLinerChange A-dimension limit for alarm C27 (Parameter 503)
Crusher1.AI.AI_Power Current Power
Crusher1.Double.PowerAvg Current average power, 0 - 1000
Crusher1.Integer.CurrentMaxPower The crushers max power according to the selected crushing program, 0 - 10000
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Crusher1.Integer.MaxMotorPower Max permissible continuous power output from the motor, 0 - 1000 (parameter 502)
Crusher1.Integer.MaxPower The crushers max input power 0 - 1000 (parameter 601)
Crusher1.Integer.IdlePower Power when the crusher is considered idle
Crusher1.AI.AI_OilTemp Current return oil temperature, 0 - 200
Crusher1.AI.AI_Pressure Current pressure, 0 - 25
Crusher1.Double.Pressure MeterMax 100% allowed pressure load
Crusher1.Integer.CurrentRunMode The crushers current run mode. 1 = Stop, 2 = Manual, 3 = Auto, 4 = Calibration
Crusher1.Integer.StartCrushingProgram Sets the current running mode of the crusher. 1 = Stop, 2 = Manual, 3 = Auto
Crusher1.Boolean.CrushingProgramError True = Error in selected crushing program
Crusher1..CurrentCrusherProg The currently selected crushing program
Crusher1.Boolean.CrusherLoaded True = The crusher is considered to be loaded
Crusher1.String.CrusherType Name of the crusher Type
Crusher1.Integer.CalState State during calibration (0-11)
Crusher1.Integer.HeartBeat_Integer Heart beat value that increments 1 with every program loop
Crusher1.Integer.TrafficLight_GreenOn 1 = The green light of the traffic light is lit
Crusher1.Integer.TrafficLight_RedOn 1 = The red light of the traffic light is lit
Crusher1.Integer.TrafficLight_YellowOn 1 = The yellow light of the traffic light is lit
Crusher1.Boolean.ActiveUnackedAorBAlarm True if there is an active unacknowledged A or B alarm. Causes the status row to blink
Crusher1.Double.AlarmLubricationOilTemp Temperature limit for alarm B15 (parameter 507)
Crusher1.Alarm.A.Alarm_A01 A01 No pressure signal
Crusher1.Alarm.A.Alarm_A02 A02 No A-dimension signal
Crusher1.Alarm.A.Alarm_A03 A03 Power signal too high
Crusher1.Alarm.A.Alarm_A04 A04 Pressure signal too high
Crusher1.Alarm.A.Alarm_A05 A05 A-dimension signal too high
Crusher1.Alarm.B.Alarm_B10 B10 Oil temperature signal too high
Crusher1.Alarm.B.Alarm_B11 B11 No power signal
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Crusher1.Alarm.B.Alarm_B12 B12 Shaft at bottom posiont under load
Crusher1.Alarm.B.Alarm_B14 B14 Hydroset pump motor protector tripped
Crusher1.Alarm.B.Alarm_B15 B15 Return oil too hot
Crusher1.Alarm.B.Alarm_B16 B16 'Pump up' response time too long
Crusher1.Alarm.B.Alarm_B17 B17 'Pump down' response time too long
Crusher1.Alarm.B.Alarm_B18 B18 'Pump up' command too long
Crusher1.Alarm.B.Alarm_B19 B19 'Pump down' command too long
Crusher1.Alarm.B.Alarm_B20 B20 No communication with power measurement unit
Crusher1.Alarm.B.Alarm_B21 B21 No communication with tank measurement unit
Crusher1.Alarm.B.Alarm_B22 B22 No communication with hydroset drive unit
Crusher1.Alarm.B.Alarm_B23 B23 Power to low compared to pressure
Crusher1.Alarm.B.Alarm_B24 B24 Pressure too low compared to power
Crusher1.Alarm.C.Alarm_C21 C21 No return oil temperature signal
Crusher1.Alarm.C.Alarm_C23 C23 Mainshaft at bottom position
Crusher1.Alarm.C.Alarm_C24 C24 Mainshaft at top position
Crusher1.Alarm.C.Alarm_C27 C27 Liner change necessary
Crusher1.Alarm.C.Alarm_C28 C28 Calibration needed
Crusher1.Alarm.C.Alarm_C29 C29 Axel does not move up
Crusher1.Alarm.C.Alarm_C30 C30 Axel does not move down
Crusher1.Alarm.C.Alarm_C31 C31 Axel moves up too slowly
Crusher1.Alarm.C.Alarm_C32 C32 Axel moves down too slowly
Crusher1.Double.Stat_CssAvgLast30Min Average CSS for the latest 30 minutes
Crusher1.Double.Stat_CssMaxLast30Min Max CSS for the latest 30 minutes
Crusher1.Double.Stat_CssMinLast30Min Min Css for the latest 30 minutes
Crusher1.Double.Stat_PowerAvgLast30Min Average power for the latest 30 minutes
Crusher1.Double.Stat_PowerMaxLast30Min Max Power for the latest 30 minutes
Crusher1.Double.Stat_RemainingShaftTravel Remaining shaft travel at current CSS
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Crusher1.Double.Stat_TimeSinceCalibrationLoad The total time that the crusher has been loaded since the last calibration
Crusher1.Double.Stat_TimeSinceLinersChangeLoad The total time that the crusher has been loaded since the liners where changed
Crusher1.Double.Stat_EnergyConsumptionSinceMantleChange The total energy consumption since the last mantle change