BENSHAW EMX4e User manual

Benshaw retains the right to change specications and illustrations in text without prior notication.
The contents of this document may not be copied without the explicit permission of Benshaw.
©2020 Benshaw, Inc
710-21972-00A
Probus
Communications option
for EMX4e/EMX4i soft starters
User Guide

Product Compatibility
This expansion card is suitable for use with EMX4e and EMX4i soft starters.
Product description Soft starter name
Basic model EMX4e
Advanced model EMX4i
Parameter Management
Parameter lists vary according to the model and version of soft starter.
Refer to the relevant soft starter literature for a complete parameter list.
For the latest manuals and software, please visit our website.

Contents
1Disclaimer .......................................................................................................................... 2
2Warnings............................................................................................................................ 2
3Important User Information .............................................................................................. 2
4Installation ......................................................................................................................... 3
5Configuration..................................................................................................................... 4
6Data Structures.................................................................................................................. 5
7Profibus Diagnostic Telegram and Flag ........................................................................ 11
8Profibus Freeze Mode ..................................................................................................... 11
9Profibus Sync Mode ........................................................................................................ 11
10 Profibus Clear Mode........................................................................................................ 11
11 Specifications .................................................................................................................. 12
Instructions 1

Disclaimer Profibus Card
1 Disclaimer
The examples and diagrams in this manual are included solely for illustrative purposes. The
information contained in this manual is subject to change at any time and without prior
notice. In no event will responsibility or liability be accepted for direct, indirect or
consequential damages resulting from the use or application of this equipment.
2 Warnings
WARNING
For your safety, isolate the soft starter from mains voltage before attaching or
removing accessories.
WARNING
Inserting foreign objects or touching the inside of the starter while the expansion
port cover is open may endanger personnel, and can damage the starter.
3 Important User Information
Observe all necessary safety precautions when controlling the soft starter remotely. Alert
personnel that machinery may start without warning.
It is the installer's responsibility to follow all instructions in this manual and to follow correct
electrical practice.
Use all internationally recognised standard practice for RS-485 communications when
installing and using this equipment.
2 Instructions

Profibus Card Installation
4 Installation
4.1 Installing the Expansion Card
1. Push a small flat-bladed screwdriver into the slot in the centre of the expansion port
cover, and ease the cover away from the starter.
2. Line up the card with the expansion port. Gently push the card along the guide rails until
it clicks into the starter.
B4 B5 10
1112 13 14 1521 22
3334 41 42 44 53 54
B4 B5 10
1
112 13 1415 2122
3334 41 42 44 53 54
1 2
18931.A
4.2 Connecting to the Network
After the card is in place, control power can be restored and field wiring can be connected
via the DB9 plug.
DB9 connector
Pin No.
Assignment
1
Shield
2
24 VDC negative (optional)
3
RxD/TxD-P
4
Not used
5
DGND
6
VP (end of bus slave only)
7 24 VDC positive (optional)
8
RxD/TxD/-N
9
DGND
4.3 Feedback LEDs
Off
On
Power (red)
Device is not powered up.
Device is powered up and ready to
go online
Network (green)
No connection, offline or data
exchange failure
Device is online and in data
exchange state
NOTE
If communication is inactive, the soft starter may trip on Network Communications.
If parameter 6M Network Communications is set to 'Soft Trip and Log' or 'Trip
Starter', the soft starter will require a reset.
NOTE
If communication fails between the device and the network, the Bus Status LED will
go off. When communication is restored, the Bus Status LED will come back on.
Instructions 3

Configuration Profibus Card
5 Configuration
Import the latest .gsd file into your Master configuration tool. This file is available from your
supplier.
If your Master uses on-screen icons, two graphic bitmap files are available from the
website. SSPM_N.bmp indicates normal mode. SSPM_D.bmp indicates diagnostic mode.
5.1 Profibus Address
The network address for the card must be set via the soft starter (parameter 12G Profibus
Address). For details on how to configure the soft starter, see the soft starter user manual.
NOTE
The Profibus Card will read the network address from the soft starter when control
power is applied. If parameters are changed in the starter, control power must be
cycled for the new values to take effect.
5.2 Enabling Network Control
The soft starter will only accept commands from the Profibus Card if parameter 1A
Command Source is set to 'Network'.
NOTE
If the reset input is active, the starter will not operate. If a reset switch is not
required, fit a link across terminals 10, 11 on the soft starter.
If the Profibus network fails, the device will leave data exchange mode after the network
watchdog timeout period has expired. This timeout period is set at the Master configuration
tool.
A Communication Timeout parameter in the GSD file sets how soon after this event the soft
starter will be forced into a trip state.
The user can adjust the Communication Timeout parameter in the GSD file to any setting
between 0 and 100 seconds. The default setting is 10 seconds.
NOTE
If the Communication Timeout parameter is set to 0, the current state of the soft
starter will remain unchanged on a network failure. This gives the user the option of
operating the soft starter via local control, but is NOT failsafe.
4 Instructions

Profibus Card Data Structures
6 Data Structures
The GSD file contains three operating modules, supporting data I/O structures as follows:
Data Structure Basic Module Extended Module
Parameter Upload/
Download Module
Soft Starter Control I/O Data
Structure on page 6 
Soft Starter Monitoring I/O
Data Structure on page 7 
Soft Starter Programming I/O
Data Structure on page 9 
The Basic Module allows the user to start and stop the soft starter and read limited
information on operating status.
The Extended Module defines additional bytes allowing the user to read soft starter
operating data such as actual motor current and motor temperature.
The Parameter Upload/Download Module allows the user to read and write soft starter
parameter values.
NOTE
The available features and parameter details may vary according to the model and
software version of the starter. Refer to the soft starter user manual for details of
parameters and supported features.
Instructions 5

Data Structures Profibus Card
6.1 Soft Starter Control I/O Data Structure
Master > Slave control word is structured as follows:
Byte
Bits
Details
0
0 to 1
Reserved
2 to 3
0 = Use soft starter remote input to select motor set
1 = Use primary motor set when starting
2 = Use secondary motor set when starting
4 = Reserved
4
0 = stop action will be a soft stop (as selected on the soft starter)
1 = stop action will be a quick stop (ie coast to stop)
5 to 7
Reserved
1
0
0 = Stop
1 = Start
1 to 2
Reserved
3
1 = Reset
4 to 7
Reserved
NOTE
Bit 4 of byte 0 must be set to 0 for the soft starter to perform a start.
Slave > Master status word is structured as follows:
Byte
Bits
Details
0
0 to 5
Motor current (% FLC)
6
Command source
0 = Network
1 = Remote Keypad, Digital Input, Clock
7
1 = Ramping (starting or stopping)
1
0
1 = Ready
1
1 = Starting, running or stopping
2
1 = Tripped
3
1 = Warning
4 to 7
Reserved
1Motor current (% FLC) represents current as a percentage of the set motor full load
current. A maximum value of 63 represents 200% full load current. To convert this value to
a readable percentage, divide by 0.315. For models 0064B and smaller this value will be 10
times greater than the value displayed on the keypad.
6 Instructions

Profibus Card Data Structures
6.2 Soft Starter Monitoring I/O Data Structure
Master > Slave output bytes are structured as follows.
Byte 2
Operating data request (Data request numbers 1 to 16)
Slave > Master input bytes, in response to an operating data request, are structured as
follows:
Byte 2
Echo data request number
Byte 3
Bits 7 to 1 Reserved
Bit 0 = 1: Invalid data request number
Byte 4
Data value (high byte)
Byte 5
Data value (low byte)
NOTE
An invalid data request number will result in the invalid data request number bit
being set = 1.
Data values are defined as follows:
Data
Request
Number
Description
Bits
Details
0
Reserved
1
Product information
0 to 7
Reserved
8 to 15
Product type code:
12 = basic model
13 = advanced model
2
Starter state
0 to 3
1 = Ready
2 = Starting
3 = Running
4 = Stopping (including braking)
5 = Not ready (restart delay, restart temperature
check, run simulation, reset input is open)
6 = Tripped
7 = Programming mode
8 = Jog forward
9 = Jog reverse
4
0 = Negative phase sequence
1 = Positive phase sequence (only valid if
bit 6 = 1)
5
1 = Current exceeds FLC
6
0 = Uninitialised
1 = Initialised
7
1 = Communication error between device and
soft starter
8 to 15
See Trip Codes on page 9
Instructions 7

Data Structures Profibus Card
Data
Request
Number
Description
Bits
Details
3
Motor current
0 to 7
Average rms current across all three phases
(low byte)
8 to 15
Average rms current across all three phases
(high byte)
4
Motor temperature
0 to 7
Motor thermal model (%)
8 to 15
Reserved
5
% Power factor
0 to 7
100% = power factor of 1
8 to 15
Reserved
6
Power (kW)
0 to 11
Power
12 to 15
Power scale
0 = Multiply power by 10 to get W
1 = Multiply power by 100 to get W
2 = Power (kW)
3 = Multiply power by 10 to get kW
7
Power (kVA)
0 to 11
Power
12 to 15
Power scale
0 = Multiply power by 10 to get VA
1 = Multiply power by 100 to get VA
2 = Power (kVA)
3 = Multiply power by 10 to get kVA
8
Voltage
0 to 13
Average rms voltage across all three phases
14 to 15
Reserved
9
Current
0 to 13
Phase 1 current (rms)
14 to 15
Reserved
10
Current
0 to 13
Phase 2 current (rms)
14 to 15
Reserved
11
Current
0 to 13
Phase 3 current (rms)
14 to 15
Reserved
12
Voltage
0 to 13
Phase 1 voltage
14 to 15
Reserved
13
Voltage
0 to 13
Phase 2 voltage
14 to 15
Reserved
14
Voltage
0 to 13
Phase 3 voltage
14 to 15
Reserved
15
Version
0 to 7
Software minor revision number
8 to 15
Software major version number
16
Digital input state
For all inputs, 0 = open, 1 = closed (shorted)
0
Start/Stop
1
Reserved
2
Reset
3
Input A
4
Input B
5 to 15
Reserved
8 Instructions

Profibus Card Data Structures
6.3 Soft Starter Programming I/O Data Structure
The Soft Starter Programming I/O Data Structure allows the user to upload (read) and
download (write) soft starter parameter values over the network.
CAUTION
Do not change the default values of the Advanced parameters (parameter group
20). Changing these values may cause unpredictable behaviour in the soft starter.
Outputs
Master > Slave output bytes are structured as follows.
Byte
Bits
Details
3
0 to 7
Parameter number to read/write
4
0
Reserved
1
1 = Read parameter
2
1 = Write parameter
3 to 7
Reserved
5
0 to 7
High byte parameter value to write to soft starter/ zero data values
for read
6
0 to 7
Low byte parameter value to write to soft starter/ zero data values
for read
Inputs
Slave > Master input bytes are structured as follows.
Byte
Bits
Details
6
0 to 7
Echo parameter number
7
0
1 = Invalid parameter number
1
1 = Invalid parameter value
2 to 7
Reserved
8
0 to 7
High byte parameter value read from soft starter
9
0 to 7
Low byte parameter value read from soft starter
6.4 Trip Codes
Trip Code
Description
0
No trip
1
Excess start time
2
Motor overload
3
Motor thermistor
4
Current imbalance
5
Frequency
6
Phase sequence
7
Instantaneous overcurrent
8
Power loss
9
Undercurrent
10
Heatsink overtemperature
11
Motor connection
12 Input A trip
Instructions 9

Data Structures Profibus Card
Trip Code
Description
13
FLC too high
14
Unsupported option (function not available in inside delta)
15
Communications card fault
16
Forced network trip
17
Internal fault
18 Overvoltage
19
Undervoltage
23
Parameter out of range
24
Input B trip
26
L1 phase loss
27
L2 phase loss
28
L3 phase loss
29
L1-T1 shorted
30
L2-T2 shorted
31
L3-T3 shorted
33
Time-overcurrent (Bypass overload)
34
SCR overtemperature
35
Battery/clock
36
Thermistor circuit
47
Overpower
48
Underpower
56
Keypad disconnected
57
Zero Speed Detect
58
SCR Itsm
59
Instantaneous overcurrent
60
Rating Capacity
70
Current Read Err L1
71
Current Read Err L2
72
Current Read Err L3
73
Remove Mains Volts (mains voltage connected in run simulation)
74
Motor Connection T1
75
Motor Connection T2
76
Motor Connection T3
77
Firing Fail P1
78
Firing Fail P2
79
Firing Fail P3
80
VZC Fail P1
81
VZC Fail P2
82
VZC Fail P3
83
Low Control Volts
84~96
Internal fault x. Contact your local supplier with the fault code (X).
10 Instructions

Profibus Card Profibus Diagnostic Telegram and Flag
7 Profibus Diagnostic Telegram and Flag
The Profibus Card supports external diagnostics. The following telegram will be sent to the
Master if the soft starter trips or if a parameter is changed at the soft starter.
Diagnostic Telegram Data Structure
Byte 0
User diagnostic length (Always set = 3)
Byte 1
Trip Code
Byte 2
Changed parameter number
Profibus Trip Code
When the soft starter trips, a diagnostic flag is set at the Master and the trip code is
reported in Byte 1. When the soft starter is reset, the diagnostic flag and trip code data are
reset = 0, provided the trip condition does not still exist (see Trip Codes on page 9).
Changed Parameter Number
If a parameter is changed via the keypad, the affected parameter number is reported in
Byte 2. When the Master reads or writes the changed parameter, Byte 2 is reset = 0.
A changed parameter number does not set a diagnostic flag.
8 Profibus Freeze Mode
The Profibus Card supports Freeze Mode.
In Freeze Mode, inputs are only updated with new data from the soft starter when another
Freeze action is carried out. An Un-Freeze action returns the device to normal operation.
9 Profibus Sync Mode
The Profibus Card supports Sync Mode.
In Sync Mode, commands to the soft starter are not processed until another Sync action is
carried out. An Un-Sync action returns the device to normal operation.
10 Profibus Clear Mode
If the Master sends a global Clear command, the device will send a Quick Stop command
to the soft starter.
Instructions 11

Specifications Profibus Card
11 Specifications
•Connections
Soft starter ........................................................................................ 6-way pin assembly
Network ................................. 5-way male and unpluggable female connector (supplied)
Maximum cable size ........................................................................................... 2.5 mm2
•Settings
Address range .................................................................................................... 1 to 125
Data rate (bps) ............................................................ 9.6 kb/s ~ 12.0 Mb/s (auto-detect)
•Certification
CE ............................................................................................................. EN 60947-4-2
RoHS ................................................................ Compliant with EU Directive 2011/65/EU
Profibus International ................................................................................
12 Instructions

BENSHAW
615 Alpha Drive
Pisburgh, PA 15238
Phones: [phone]
Fax: [phone]
BENSHAW Canada
550 Bright Street
Listowel, Ontario N4W 3W3
Phone: [phone]
Fax: [phone]
È710-21972-00ANËÍ
710-21972-00A