Reliable functioning of analyzers is of decisive importance for process control. It is necessary to record, correct and transmit measured values, to set and modify parameters, to check functions, to update calibrations, and to scan status signals e.g. for preventive maintenance. Communication between the operator and device is therefore an important part of process analysis, and the offered facilities have become a decisive performance feature of analyzers.

Extractive continuous process gas analysis

The gas analyzers of Series 6 (ULTRAMAT 6, ULTRAMAT/OXYMAT 6, OXYMAT 6, OXYMAT 61, OXYMAT 64, FIDAMAT 6, CALOMAT 6, CALOMAT 62) as well as the ULTRAMAT 23 offer the following communication options in addition to data transmission with analog and digital outputs:

• RS 485 interface
• SIPROM GA
• PROFIBUS DP/PA
• Generic communications interface (only OXYMAT 6, ULTRAMAT 6 and ULTRAMAT/OXYMAT 6).

The modular SIPROCESS GA700 gas analyzer with the ULTRAMAT 7, OXYMAT 7 and CALOMAT 7 modules offers the following communication options in addition to data transmission with analog and digital outputs:

• MODBUS TCP
• Remote transmission via UMTS router
• Modbus TCP/PROFINET communication

RS 485 interface

The serial interface integrated as standard permits communication between several analyzers over the internal bus (ELAN). Parameterization is carried out using the analyzer's menu.

Networking over ELAN

ELAN communication is used e.g. for the interference gas correction of interfering gases. Direct connection is only possible between Siemens gas analyzers.

Bus cable with plug connections, ELAN networking

• Bus terminating resistors
  Pins 3-7 and 8-9 of the first connector of a bus cable must be bridged (ELAN networking).

Note

If the cable is longer than 500 m or high interference effects are present, it is advisable to install a repeater on the device side.

Networking with SIPROM GA

When used externally, the RS-485 interface requires software matched to the analyzers, e.g. SIPROM GA.

SIPROM GA is a software program for communication between a PC or laptop and analyzers. A maximum of 12 devices (electronics modules) with up to four channels/measured components of the following type can be connected, displayed and remote-controlled per COM interface:

• OXYMAT 6/61
• OXYMAT 64
• ULTRAMAT 6
• CALOMAT 6
• CALOMAT 62
• FIDAMAT 6
• ULTRAMAT 23

SIPROM GA allows access to device parameters all the way to the device configuration. All analyzer functions (except factory default functions) can be remote-controlled and monitored in this manner. SIPROM GA is therefore an ideal service and maintenance tool for Siemens gas analyzers.

In addition to remote control of all operator functions, SIPROM GA offers full access to all diagnostic data. SIPROM GA therefore permits preventive maintenance as well as fast responses when maintenance becomes necessary or when the production process is changed.

SIPROM GA guarantees:

• High operational reliability
• High availability
• Central, comprehensive information
• Fast response time
• Flexibility
• Economical system integration

In addition to the display of analyzers with TAG No., components, current measured values, comprehensive diagnostics information (status) and parameter assignment, SIPROM GA also offers the following possibilities:

• Bargraph display
• Recorder display of one or more measured values with printer output
• Calibration functions (adjustment of all setpoints for calibration, remote calibration)
• Saving of all device data
• Remote control of all device functions
• Remote calibration
• Online help
• Downloading of new device firmware
• Cyclic saving of measured values on hard disk
• Writing user data to the device's EEPROM, or downloading data from it.

Analyzers are accessed using SIPROM GA in one of the following two ways:

• Directly from the PC with an RS 485 interface
• Via an Ethernet gateway

Hardware requirements

In order to use SIPROM GA, the following hardware and system requirements for the PC/laptop equipment must be met:

• Windows computer with Pentium 133 MHz and 32 MB RAM:
  Recommendation: Pentium II 266 MHz and 64 MB RAM
• CD-ROM drive (for installation)
• Free hard disk capacity of at least 10 MB
• VGA graphics card (Windows-supported);
  resolution: 1024 x 768
• Printer (Windows-supported)
• MS Windows 95, ME; NT 4, Windows 98, Windows 2000, Windows XP, or Windows 7 operating system
• Vacant COM port (COM 1, 2 ...)
  • The RS 485 / RS 232 interface converter is required for the connection to the RS 485 ELAN network
  • A standard 10 Mbit or 100 Mbit network (RJ45 connection) with TCP/ IP is required for connection of the Ethernet / RS 485 interface converter

Accessories for the network

For cables, connectors, repeaters etc., see Catalog IK PI or in the Mall in CA 01 under SIMATIC NET communications systems / PROFIBUS / Network components.

Networking with SIPROM GA via converter

A maximum of 12 analyzers with up to four components each can be networked.

The functional principle is shown in the following illustration.

Typical structure of an RS 485 Ethernet network via SIPROM GA

The gas analyzers can be installed at distances up to 500 m. One network can be connected to each COM port.

Networking with SIPROM GA via Ethernet

For access via Ethernet, there are no limitations on the distance between PC and gateway. In addition, communication via Ethernet enables the installation of multiple gateways on one COM port. As a result, the possibility exists for operator control and monitoring of multiple analyzers or analyzer systems located far away and far apart from one station.

Typical structure of an RS 485 Ethernet network via SIPROM GA

PROFIBUS

The commonly used practice of transmitting measured values and fault messages via analog and digital outputs requires complex cabling. By contrast, with PROFIBUS DP and PROFIBUS PA, a single 2-wire cable is possible for digital transmission of, for example, all measured values (including from several channels), status information and diagnostics functions for preventive maintenance.

The PROFIBUS DP version is widely used in production automation because of its high transmission rate for relatively small data quantities per device. PROFIBUS PA makes allowance, in particular, for the properties required in process industry, e.g. large data quantities and use in hazardous areas.

The limited dynamic performance of 4 to 20 mA mA signals can be replaced, the laborious configuring of measuring ranges can be omitted. By using simulated measured values without media, increased safety can be provided for the plant configuration, and configuration errors can be avoided. Parameter sets can be generated offline (from your desk) and subsequently downloaded and saved in the device. Local operations can thus be reduced to a minimum.

With an optional plug-in card, which can also be retrofitted, the following Siemens gas analyzers are PROFIBUS-compatible and comply with the mandatory "Device profile for analyzers" of the PI (PROFIBUS International).

• OXYMAT 6/61
• OXYMAT 64
• ULTRAMAT 23
• ULTRAMAT 6
• CALOMAT 6
• CALOMAT 62
• FIDAMAT 6

Customer benefits include enormous savings potential in all plant areas, covering configuration and commissioning, operation and maintenance, up to subsequent plant expansions.

Operation of the gas analyzers from a control system or a separate PC is possible with the SIMATIC PDM tool (Process Device Manager). The SIMATIC PDM software runs on Windows and can be integrated in the SIMATIC PCS 7 process control system. This permits a clear presentation for integration of the analyzers in the system as well as for the complex parameter structure of the analyzers.

Direct connection of the analyzers to a control system without PDM, e.g. using STEP 7, is also possible but this requires additional programming and is less convenient for the operator. In most cases, this direct connection is therefore only applicable if acyclic (device operation) data are not used.

A differentiation is made between cyclic and acyclic services. Cyclic services are used to transmit time-critical data such as measured values and statuses. The acyclic services allow device parameters to be queried or changed during operation.

Both graphic displays and values can be output on a PC. Signaling of maintenance, fault and diagnostics information is also cyclic. These data are displayed in plain text when using SIMATIC PDM.

The digital outputs can also be switched using cyclic services, thus also permitting triggering of relays over PROFIBUS (e.g. for measuring point switchover, calibration etc.).

Schematic structure of a PROFIBUS system

The following acyclic device parameters and device configurations can be used in PROFIBUS DP and PROFIBUS PA with SIMATIC PDM:

• Factory data
• Diagnostics values
• Logbook
• Display measuring ranges
• Zero calibration
• Sensitivity calibration
• Zero point/sensitivity setpoints
• Total/single calibration and AUTOCAL
• Select measuring ranges
• Define measuring ranges
• Electrical time constants
• On/off functions
• Chopper frequency
• Magnetic field frequency
• Date/time
• Measuring point switchover
• Logbook settings
• Relay assignment
• Digital inputs
• Reset
• Save/load data
• Suppression of short noise signals
• Calibration tolerances
• Switch valves
• PROFIBUS configuration

Use of PROFIBUS offers the following customer benefits:

• Cost reductions for planning, installation and operation
• Use of (distributed) device intelligence
• Replaceability of devices
• Only one cable for everything, no complex cabling
• No limited 4 to 20 mA resolution
• No laborious parameterization of measuring ranges
• Simulation of measured values
• Simplification of commissioning
• Testing of network/AS
• Avoidance of errors during startup
• Online diagnostics
• Offline parameterization

Generic communications interface
(only OXYMAT 6, ULTRAMAT 6 and ULTRAMAT/OXYMAT 6)

Users benefit from numerous functions that are mainly needed in the automotive industry, for example, to carry out repeated linearization. In contrast to PROFIBUS and ELAN, communication is only possible between one device and one PC, and takes place according to the master/slave principle. The device only transmits data when requested by a command telegram, where only one command can be processed and replied to at a time.

Function88 can be used to open the generic communications menu and set the parameters.

SIPROCESS GA700: connection via Modbus TCP

Der SIPROCESS GA700 uses Modbus TCP for interference gas corrections and for external pressures for measured value processing. Measured values such as process value, pressure and temperature can also be imported from other SIPROCESS‑GA700‐devices and shown on the display.

The SIPROCESS GA700 can simultaneously accept up to seven connections via Modbus TCP.
Modbus TCP function codes 3, 16 and 43 are currently supported:

• Current measured values such as process value, pressure, temperature and device status can be determined with function code 3.
• Device identification data are made available using function code 43.
• The eight virtual Modbus digital inputs can be written with function code 16.

The virtual digital inputs can be freely configured just like the physical inputs. As a result for example, it is possible to start an AutoCAL, set external errors and switch between various measuring ranges via Modbus TCP.

SIPROCESS GA700: Possible communication paths

The SIPROCESS GA700 has two Ethernet interfaces: one process interface and one service interface.
While the device is connected to the plant bus, device parameters can be assigned in parallel via the service interface.

• The process and service interfaces are interconnected (switch functionality).
• There is no limit on the number of SIPROCESS GA700 devices in an Ethernet network.
• The device parameters are assigned using SIMATIC PDM (Ethernet).
• The SIPROCESS GA700 can be connected to a controller via Modbus TCP.
  An additional Modbus library is needed for SIMATIC PCS 7 (SIMATIC S7‑400).
  A standard block (SIMATIC PCS 7 SIMATIC S7‑400: MonAna/MonAnl) is used to acquire and display the values. As a result, the data is also available in WinCC.

The parameter assignment using SIMATIC PDM is also possible via a point-to-point connection with the SIPROCESS GA700.

Close-distance and long-distance remote access to the SIPROCESS GA700 can also be set up using standard network components (WLAN access point / UMTS router / DSL router). The following figure shows a selection of possible communication paths and network components that the SIPROCESS GA700 can use for communication.

SIPROCESS GA700: Communication paths and network components

With a Modbus TCP/PROFINET gateway, the SIPROCESS GA700 can also be connected to a controller via PROFINET.

Connection of two separate networks (e.g. multiple locations) via the Internet.

A VPN tunnel is set up over the Internet between a UMTS router (plant environment) and an ADSL router (office environment). All SIPROCESS GA700 devices can now be addressed from any node using, for example, SIMATIC PDM/controller/Modbus client in one of the two networks via Modbus TCP and S7-400 (PDM).

Remote access

The WLAN access point enables mobile access to devices via a laptop, for example. If a PDM web server was installed and set up, you can access the SIPROCESS GA700 devices from hand-held devices (mobile phone, tablet) via a web browser. The PDM web server is a computer on which SIMATIC PDM with additional web server functionalities is installed.

In-situ continuous process gas analysis

LDS 6 can send and receive data over an Ethernet connection with the help of the LDScom software. This installation and service tool is able to check and adapt device status and calibration parameters from a remote location. If necessary, even a complete system check can be carried out over the remote connection. If servicing is necessary, the required information can be sent to the Siemens service engineer by router, and he can then carry out the appropriate measures from the remote location.

This facility for remote maintenance and diagnostics is implemented using a standard LAN modem.

External connection of LDS 6 via a modem for implementing remote maintenance measures