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Profibus is one of the most widely used and successful fieldbus systems in industrial automation, known for its open architecture and compatibility across different manufacturers. It allows various automation devices to communicate seamlessly through a common interface protocol, making it highly versatile for integration. Among its variants, Profibus-DP (Distributed I/O) is specifically designed for high-speed, time-critical communication between control systems and field devices. This makes it ideal for applications like remote I/O systems where fast, periodic data exchange is essential. Through the Profibus-DP network, devices such as PLCs, smart sensors, and inverters can engage in bidirectional digital communication, enabling seamless connectivity with systems from multiple vendors.
Jigang Gangde Color Plate Co., Ltd., a large-scale color plate production facility established in 2003 by Jinan Iron and Steel Group Corporation, relies on a gas system that includes curing furnaces, heat-conducting oil furnaces, and gas hydrogen production units. The gas pressurizing machine plays a critical role in this process, undergoing secondary pressurization to meet the operational requirements. To ensure efficient and reliable control, the company implemented a Profibus-DP communication system, integrating Siemens S7-300 PLCs and ABB ACS600 inverters from different manufacturers.
The system configuration involves using Siemens and ABB products to create a fully digital AC speed control network over the Profibus-DP bus. The central controller is a Siemens SIMATIC S7-315-2DP PLC, while the ABB ACS600 inverters are connected via NPBA-12 communication modules. Programming is done using STEP7 V5.2 software, which handles hardware configuration, network setup, and communication protocols. The upper-level human-machine interface (HMI) is managed through WinCC 5.1, and the PLC communicates via Ethernet.
In terms of communication protocol, the S7-300 PLC acts as the master station, sending commands to the inverter (slave station) and receiving status and fault information. The NPBA-12 module facilitates this by storing process data in bidirectional RAM, allowing the inverter to access parameters such as control words, setpoints, and diagnostic data. The Profibus-DP protocol organizes data into headers, network data, and protocol layers. Network data consists of PPO (Process Parameter Object) structures, which include PKW (parameter values) and PZD (process data). These are categorized based on their function, ensuring that parameter and process data transmission do not interfere with each other.
In the STEP7 project, the hardware was configured using the Hardware Configure tool, and the GSD file for the NPBA-12 module was imported. The PPO type (PPO4) was selected, and the site address was assigned. Two system function blocks, SFC14 and SFC15, were used to read and write data between the PLC and the inverter. A data block was created for inverter communication, and a variable table was set up to monitor real-time performance.
Before full operation, the inverters required specific parameter settings. Basic settings included defining the module type, selecting the communication protocol (Profibus-DP), choosing the appropriate PPO type, and assigning device addresses. For example, inverters were set to stations 2 and 3. Process parameters were also configured, specifying how data would be exchanged between the PLC and the inverter. PZD1 and PZD2 were used for control and feedback signals, respectively, enabling precise control of motor speed and monitoring of operational status.
After implementing the Profibus-DP system, the inverter control solution demonstrated strong reliability, ease of use, and flexibility in adapting to process changes. At Jigang Gangde Color Plate Co., Ltd., the system has performed well, offering a successful model for future automation projects involving multi-vendor network communication.