BIFFI ICON3000 Series User manual

Installation, Operation and Maintenance Manual
MDE 262 Rev. 2
September 2021
Bif ICON3000
Lonworks Bus Module
Copyright © Biffi. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.biffi.it or from your nearest Biffi Center:
Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: [phone] – [e-mail]

Rev. Date Description Prepared Approved
2 September 2021 General update (Migration to new template)
1 August 2021 Updated to ICON3000 Series F.Paciotti C. Doglio
0 February 2015 First Issue as part of MAN618-5 C. Doglio A.Affaticati
Revision Details
September 2021
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MDE 262 Rev. 2
Revision Details

i
Table of Contents
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Table of Contents
Table of Contents
Section 1: Introduction to LonWorks Protocol
1.1 Nodes Addressing ......................................................................................... 4
1.2 Message Services .......................................................................................... 4
Section 2: LonWorks Implementation in ICON3000
2.1 Fieldbus Media .............................................................................................. 5
2.1.1 Specication for 16 AWG / 1.3 mm – Twisted Pair Cable ..................... 6
2.1.2 Bus Communication Topology............................................................ 7
Section 3: ICON3000 LonWorks Interface
3.1 Network Wiring ............................................................................................ 9
3.2 LD1-LD5: Status LED.................................................................................... 10
3.3 LD6: Service LED ......................................................................................... 11
3.4 Local Procedures......................................................................................... 12
3.4.1 FDI Control Menu ............................................................................. 12
3.4.2 Positioner Menu ............................................................................... 14
3.4.3 Node Report Menu........................................................................... 15
3.4.4 Service Pin Message ......................................................................... 16
Section 4: ICON3000 LonWorks Communication Prole
4.1 Actuator Runtime Input Variables................................................................ 17
4.2 Actuator Output Variables........................................................................... 18
4.3 Actuator Setup and Conguration Variables................................................ 20
4.4 Maintenance Variables ................................................................................ 22
4.5 Factory Commissioning Variables (Read Only)............................................. 22
4.6 Fault Detection Function Conguration....................................................... 23

Notes
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Introduction to LonWorks Protocol 1
Section 1: Introduction to LonWorks Protocol
Section 1: Introduction to LonWorks Protocol
LonWorks is a complete platform for implementing control network systems created
by Echelon Corporation. LonWorks has been approved as ANSI/EIA-709.1 and as
ISO/IEC 14908, Parts 1, 2, 3, and 4 Standards.
Devices in a LonWorks network communicate using LonTalk®, the standardized language
of the network. LonTalk consists of a series of underlying protocols that allow intelligent
communication among various devices on a network. The protocol provides a set of
services that allow the application program in a device to send and receive messages
from other devices over the network without needing to know the topology of the network
or the names, addresses or functions of other devices. Support for network management
services allow for remote network management tools to interact with devices over the
network, including reconguration of network addresses and parameters, downloading
of application programs, reporting of network problems and start/stop/reset of device
application programs. LonTalk – and thus LonWorks networks – can be implemented
over basically any medium, including power lines, twisted pair, radio frequency (RF),
infrared (IR), coaxial cable and bre optics.
A control network is a group of "nodes", each with one or more sensors or actuators,
plus localized computational capability, that communicate over one or more media,
using a standard protocol to control and monitoring application. Communication among
the nodes may be peer-to-peer (distributed control) or master-slave (centralized control);
in either case, intelligence in the nodes permits the distribution of processing loads. If the
control functions are also distributed, both system performance and reliability can be
dramatically enhanced.
LonWorks networks really describe a complete solution to the problem of control systems.
Protocols are generally designed to follow the ISO standard "Open Systems Interconnection
Reference Model," which encompasses a full set of protocol features, and classies them
according to seven functional categories referred to as "layers". Thus the "seven layer
ISO-OSI model".
The LonTalk protocol implements all seven layers of the ISO-OSI model and the entire
LonTalk protocol stack is contained in the Neuron chip that is a complete system on a chip.
NOTICE
Bif Italia has taken every care in collecting and verifying the documentation contained in
this Installation, Operation and Maintenance Manual. The informations herein contained
are reserved property of Bif Italia.

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Introduction to LonWorks Protocol2
Section 1: Introduction to LonWorks Protocol
The Neuron is comprised of multiple CPUs, memory, I/O, communications port, rmware,
and operating system. Features include media access, transaction acknowledgement and
peer-to-peer communication, and more advanced services such as sender authentication,
priority transmissions, duplicate message detection, automatic retries, client-server
support, unicast/multicast/broadcast addressing and error detection and recovery.
Reliable delivery is provided by using end-to-end acknowledgements made possible by the
use of a seven layer OSI stack, 16-bit cyclical redundancy checks and in the case of certain
transceivers, the use of error correction algorithms.
An integral part of the protocol used in LonWorks networks is its unique media access
technique, termed "predictive persistent CSMA, with optional priority and collision
detection". It provides linear response to offered trafc load, predictable response time for
heavily loaded networks, and consistent performance independent of network size.
User
7 - APPLICATION
6 - PRESENTATION
5 - SESSION
4 - TRANSPORT
3 - NETWORK
2 - DATA LINK
1 - PHYSICAL
Physical Medium

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Introduction to LonWorks Protocol
Interoperability is achieved by the introduction of the Standard Network Variable Type
(SNVT): each node implements a set of communication objects that are dened according
to the standardized data type SNVT.
The conguration of a LonWorks network consists of the establishing of virtual
connections among input and output communication objects belonging to the same SNVT
type (binding).
During the normal functioning, every time an output changes state, the variation is
immediately propagated to the correspondent input element.
Figure 1
3
Section 1: Introduction to LonWorks Protocol
ACTUATOR
ACTUATOR
#1
ACTUATOR
#2
ACTUATOR
#3
DCM
nvi_DriveOpen
nvi_DriveClose
nvo_ValveOpen
nvo_ValveClose
nvo_Opening
nvo_Closing
nvi_DriveOpen
nvi_DriveClose
nvo_ValveOpen
nvo_ValveClose
nvo_Opening
nvo_Closing
nvi_DriveOpen
nvi_DriveClose
nvi_DriveClose
nvi_DriveOpen
nvo_Closing
nvo_Opening
nvo_ValveClose
nvo_ValveOpen
nvo_Closing
nvo_Opening
nvo_ValveClose
nvo_ValveOpen
nvi_input1
nvi_input2
nvi_input3
nvi_input4
nvi_input5
nvi_input6
nvi_input7
nvi_input8
nvi_input9
nvi_input10
nvi_input11
nvi_input12

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Introduction to LonWorks Protocol4
Section 1: Introduction to LonWorks Protocol
1.1 Nodes Addressing
LonTalk protocol supports networks with segments using different media. A channel is a
physical transport media for packets. A LonWorks network is composed of one or more
channels. The LonWorks devices that are physically connected to a channel can be reached
by a variety of different addressing mechanisms.
Each device is identied by a unique Neuron-ID code that is a 48-bit code assigned to the
Neuron chip microprocessor during the manufacturing. The ID is typically used as
a network address during the installation and the node conguration.
The identier that is assigned to the device during the conguration is based on
three components:
• Domain:it corresponds to the entire network. A single node can be a member of
up to two domains.
• Subnet:a subnet is a logical grouping of nodes form one or more channels.
There may be up to 255 subnets per domain.
• Node: there may be up to 127 nodes per subnet.
The addressing space available for a single domain is 255 x 127 = 32.385.
1.2 Message Services
The LonTalk protocol offers four basic type of message services.
ACKD: End-to-end acknowledged service, where a message is sent to a node or to a
group of nodes and individual acknowledgements are expected from each receiver. If the
acknowledgements are not received, the sender times out and retries the transaction.
REQUEST: Request/response service, where a message is sent to a node or to a group of
nodes and individual responses are expected from each receiver.
UNACKD_RPT: Unacknowledged repeated. A message is sent to a node or to a group of
nodes multiple times and no response is expected.
UNACKD: Unacknowledged. A message is sent once to a node or to a group of nodes time
and no response is expected.

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LonWorks Implementation in ICON3000 5
Section 2: LonWorks Implementation in ICON3000
Section 2: LonWorks Implementation
in ICON3000
2.1 Fieldbus Media
This chapter is based on the following documents:
• LONWORKS®FTT-10 Free Topology Transceiver User’s Guide - Version 6 -
Echelon® Corporation
• LONMARK™ Layers 1-6 Interoperability Guidelines - Version 3.0 - LONMARK™
Interoperability Association
• LONWORKS® Engineering Bulletin - Junction Box and Wiring Guideline for Twisted
Pair LONWORKS®Networks - November 2001
ICON3000 implements LonWorks protocol using the FTT-10A Free Topology Transceiver
that is the component that drives the communication function.
The characteristics of the FTT-10A transceiver are stated in the Echelon literature and can
be summarized as follow:
• Communication speed is set at 78 Kbps;
• The communication channel cable must be separate from the high voltage cables;
• Up to 64 FTT-10 A transceivers can be connected in a network segment;
• The network segment length depends on the network topology and on the
cable selected.
NOTE:
If the total bus length exceeds the maximum length indicated in the tables above, or if the total number
of nodes is more than 64, it is necessary to split the network in several network segments connected by
standard physical layer repeaters.
Table 1. Doubly Terminated Bus Topology Specication
Table 2. Free Topology Specication
Maximum bus length Max stub from bus to node
BELDEN 85102, 16 AWG 2,700 meters 3 meters
BELDEN 8471, 16 AWG 2,700 meters 3 meters
Level IV, 22 AWG 1,400 meters 3 meters
TIA Category 5 900 meters 3 meters
Maximum bus length Max stub from bus to node
BELDEN 85102, 16 AWG 500 meters 500 meters
BELDEN 8471, 16 AWG 400 meters 500 meters
Level IV, 22 AWG 400 meters 500 meters
TIA Category 5 250 meters 450 meters

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6
Section 2: LonWorks Implementation in ICON3000
2.1.1 Specication for 16 AWG / 1.3 mm – Twisted Pair Cable
Stranded pair (19 x 29), tinned copper.
The following Belden cables are indicates in the Echelon literature as compliant to the
16 AWG/1.3 mm – twisted pair cable specication:
BELDEN 8471 Tinned copper, PVC insulated, twisted pair, Chrome PVC jacket
BELDEN 85102 Tinned copper, Tefzel insulated. Clear Tefzel jacket. 300 V RMS 150 °C
Other selected producers are indicated in the Echelon document:
LONWORKS® Engineering Bulletin - Junction Box and Wiring Guideline for Twisted Pair
LONWORKS®Networks - November 2001
Table 3. Doubly Terminated Bus Topology Specication
Min Type Max Unit Condition
DC resistance, each conductor 14.0 14.7 15.5 ohm/km 20 °C for ASTM D 4566
DC resistance, unbalanced - - 5% - 20 °C for ASTM D 4566
Mutual capacitance - - 55.9 nF/km for ASTM D 4566
Characteristic impedance 92 100 108 ohm 64 kHz to 1 MHz for ASTM D 4566
Attenuation
20 kHz 1.3 dB/km 20 °C for ASTM D 4566
64 KHz 1.9 - -
78 KHz 2.2 - -
156 KHz 3.0 - -
256 KHz 4.8 - -
512 KHz 8.1 - -
772 KHz 11.3 - -
1000 KHz 13.7 - -
Propagation delay 5.6 ns/m 78 kHz

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LonWorks Implementation in ICON3000 7
Section 2: LonWorks Implementation in ICON3000
2.1.2 Bus Communication Topology
A Doubly Terminated Bus Topology achieves the longest bus length and in this case the
line must be terminated on both ends by a termination circuit.
The terminator is a simple RC circuit, dened by the LonWorks1 protocol specications and
shown in the drawing.
The terminators are necessary to avoid the propagation of echoes (reections) that can be
generated due to the high transmission speed (78 Kbps) and the network cable length.
R1 = 150 Ω 1%, 1/8 W
C1, C2 = 100 µF, 50 V min
Network
connection
C2
R1
C1
Figure 2 Doubly Terminated Bus Topology - Twisted Pair Termination Circuit

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ICON3000 LonWorks Interface8
Section 3: ICON3000 LonWorks Interface
J2
LD1
LD2
LD3
LD4
LD5
LD6
Service LED
Service Pin
LON
Section 3: ICON3000 LonWorks Interface
This document describes the characteristics of the LonWorks DE7761 eldbus
communication card equipped with Software 3.3.
The card is applicable to ICON2000, ICON2000v4 and ICON3000 actuators.
The Figure 3 shows the positioning of the signals and control switches available for
the user.
Figure 3

A1 A2 A3 A4 A5 A6
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ICON3000 LonWorks Interface 9
Section 3: ICON3000 LonWorks Interface
3.1 Network Wiring
The ICON3000 actuator can be installed in the LonWorks network by the twisted pair cable
connected to the screw terminals in the terminal board.
Details of the cable are available in Section 2.1.
Typically the actuators in a LonWorks network are connected in a bus structure.
Figure 4
LonWorks input data line (indicated as Side B) is connected to terminals A1- A2
(polarity insensitive); in case of shielded cable the shield is connected to terminal A3.
LonWorks output data line (indicated as Side A) is connected to terminals A4- A5
(polarity insensitive); in case of shielded cable the shield is connected to terminal A6.
Figure 5
The data lines should be kept separated from all other cables. They should be laid in
separate, conductive and earthed electrical conduits.

J2
Status LEDs
LD1 -
LD2 -
LD3 -
LD4 -
LD5 -
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ICON3000 LonWorks Interface
Figure 6
10
Section 3: ICON3000 LonWorks Interface
3.2 LD1-LD5: Status LED
Five LEDs represent the current operating status of the board. The LEDs are powered when
jumper J2 is closed.
Table 4.
CONTEXT
LED Wink Command Power Up Normal Functioning
LD1
All LEDs blink for 7 seconds
The LEDs light up in sequence
to indicate the data reading
phase from the main board.
Bus side A (net output)
ON – connected to network
OFF – connected to terminator
LD2
Bus side B (net input)
ON – connected to network
OFF – connected to terminator
LD3 Reserved
LD4 Reserved Reserved
LD5 LED is ON when the card is powered.

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ICON3000 LonWorks Interface 11
Section 3: ICON3000 LonWorks Interface
3.3 LD6: Service LED
The Service LED is controlled directly by the microprocessor that manages the LonWorks
communications and gives indications about the status of the node.
The different LED indications are shown in Table 5.
Figure 7
Figure 8
SERVICE LED
MODE
POWER APPLIED
TO NODE OFF ON
Time (s)
CONTINUOUS
REPEATED
REPEATED
CONTINUOUS
CONTINUOUS
CONTINUOUS
Service LED

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Section 3: ICON3000 LonWorks Interface
Table 5.
Mode Context Description
1Power up Bad node hardware.
2Power up Bad node hardware.
3Power up / Reset
Node is applicationless.
May be caused by the Neuron Chip rmware when a mismatch occurs on
application checksum.
Node needs to be re-programmed ashing rmware code.
4 Anytime Watchdog timer reset occurring.
Possible corrupt EEPROM or communication problem with ICON3000 base card.
5 Anytime
Node is uncongured but has an application.
This is the condition that results after the on-board procedure to return to
factory default is not completed successfully.
A new conguration from a LonWorks conguration tool restores the node.
6 Anytime Node is congured and running normally.
3.4 Local Procedures
3.4.1 FDI Control Menu
The LonWorks interface of ICON3000 is equipped with the FDI circuit that drives the
LonWorks line terminations.
The line terminations on board of the ICON3000 are supposed to be managed only by the
DCM2 Master Station because they are part of the distributed control system algorithm
that the DCM2 implements to control the communication line integrity.
Applications that do not include DCM2 must avoid the control of FDI circuits by using the
network variable nv#57 nviFdiCmd.
At the power on the terminations are released and return to the default state.
The Local operator can enter in the ICON3000 menu to verify the FDI settings and set the
default values indicate between "( )" .

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ICON3000 LonWorks Interface 13
Section 3: ICON3000 LonWorks Interface
Restore procedures:
• Move the local selector to OFF and then press simultaneously OPEN and STOP.
• LANGUAGE: Select the language and press YES.
• VIEW MODE press NO.
• Enter the password.
• SETUP MODE press YES.
• ACTUATOR SETUP press YES.
• Press NO to scroll the list of available routines until:
• FDI CONTROL press YES.
— NODE TYPE: (SLAVE): press YES if it is correct, or press NO to change.
— ADDRESS MODE: (SUBNET): press YES if it is correct, or press NO
to change.
— LOOP TIME: (250): press YES if it is correct, or press NO to change.
• CONTROL MODE: press YES to change or press NO to skip to RELAY routine.
— FDI ENABLE ALL press NO.
— FDI DISABLE ALL press YES.
• RELAY: Press YES to change or NO to return to FDI CONTROL.
— NETWORK A (ON NET) press YES if it is correct, or press NO to change.
— NETWORK B (ON NET) press YES if it is correct, or press NO to change.
View procedures:
• Move the local selector to OFF and then press simultaneously OPEN and STOP.
• LANGUAGE: Select the language and press YES.
• VIEW MODE press YES.
• Press NO to scroll the list of available routines until:
• FDI CONTROL press YES.
• Press YES to scroll the current values of FDI CONTROL parameters.

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ICON3000 LonWorks Interface14
Section 3: ICON3000 LonWorks Interface
Conguration procedures:
• Move the local selector to OFF and then press simultaneously OPEN and STOP.
• LANGUAGE: Select the language and press YES.
• VIEW MODE press NO.
• Enter the password.
• SETUP MODE press YES.
• ACTUATOR SETUP press YES.
• Press NO to scroll the list of available routines until:
• POSITIONER press YES.
— DEAD BAND: (xx): acceptable value from 0.1 to 25.5%; press YES if it is
correct, or press NO to change.
— MOTION INHIBIT TIME: (xx): acceptable value from 1 to 255 s; press YES
if it is correct, or press NO to change.
View procedures:
• Move the local selector to OFF and then press simultaneously OPEN and STOP.
• LANGUAGE: Select the language and press YES.
• VIEW MODE press YES.
• Press NO to scroll the list of available routines until:
• POSITIONER press YES.
• Press YES to scroll the current values of POSITIONER parameters.
3.4.2 Positioner Menu
The positioner function is available only on the modulating actuators and it is enabled
when the network variable nv#31 nviInchingMode has been set to the value ST_ON.
The value 0 of position request (nv#6 SetPoint), received from the LonWorks bus,
corresponds to the request R% = 0% = valve fully closed, and the value 100 corresponds to
the request R% = 100% = valve fully open.
The ICON 3000 compares the current position % of the actuator with the position request
R%, received from the bus, and if the difference is greater than the dead band, the actuator
is driven to reach the new requested position. The following options can be congured via
either bus or local operator interface:
• Dead band: congurable from 0.1% to 25.5% of the maximum position error
(difference between the position request % and current position %). The
congured value should be great enough to avoid “hunting” effect of the actuator.
! WARNING
If the dead band value set by the operator is not compatible with the position resolution
that the ICON3000 can obtain by the mechanical chain of the actuator, the ICON3000 will
use as dead band value the best resolution possible.
• Motion inhibit time: it allows to adjust the length of the delay time between
two cycles of the motor. It can be congured from 1 to 255 s and allows to set the
maximum number of start/hour of electrical motor.

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ICON3000 LonWorks Interface 15
Section 3: ICON3000 LonWorks Interface
3.4.3 Node Report Menu
It is possible to access to the signicant info related to the LonWorks interface from the
local operator interface.
• Move the local selector to OFF or REMOTE.
• Press YES or NO according to the current context to scroll the list of available
routines until:
• NODE REPORT press YES.
• Press YES to scroll the current values of NODE REPORT parameters:
— NEURON ID 6-byte unique identier assigned by the
manufacturer of the Neuron Chip.
— XMIT ERROR Transmit Error: number of CRC errors detected
during packet reception.
— TRANS. TIMEOUT Transaction Timeout: number of times that the
node failed to receive expected responses.
— RCV. TRANS. FULL Received Transaction Full: number of time that
an incoming packet was discarded.
— LOST MSG Lost Messages: number of time that an incoming
packet was discarded due to slow processing.
— MISSED MSG Missed Messages: number of time that
an incoming packet was discarded due to
excess trafc.
— RESET CAUSE Code of the last reset cause:
0 Clear
1 Power up
2 External reset
12 Watchdog
20 Software reset
— NODE STATE Code of the current node state:
2 Uncongured
3 Applicationless
4 Congured on-line
6 Congured, hard off-line
12 Congured, soft off-line
140 Congured, bypass off-line
— ERROR LOG Code of the last error detected:
0 No error
— MODEL NUMBER Set to 32.
— NODE RESET ? press YES to reset the LonWorks interface.
— CLEAR STATUS ? press YES to clear the error counters.
— PP REC COUNTER Current communication errors of the internal
data line between the logic board and the
LonWorks interface card. It is cleared if the
communication resumes.
— PP GEN COUNTER Total communication errors of the internal data
line between the logic board and the LonWorks
interface card since the last power up.