Eaton OPTCB RS-485 User manual

MN04008002E For more information visit: www.EatonElectrical.com
Siemens APOGEE™ FLN (P1) Communication Kit
User Manual
February 2006
Supersedes December 2005

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Important Notice – Please Read
The product discussed in this literature is subject to terms and conditions outlined in Eaton
Electrical Inc. selling policies. The sole source governing the rights and remedies of any
purchaser of this equipment is the relevant Eaton Electrical Inc. selling policy.
NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A
PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE
OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION,
RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN. In no event will Eaton
Electrical Inc. be responsible to the purchaser or user in contract, in tort (including
negligence), strict liability or otherwise for any special, indirect, incidental or consequential
damage or loss whatsoever, including but not limited to damage or loss of use of equipment,
plant or power system, cost of capital, loss of power, additional expenses in the use of
existing power facilities, or claims against the purchaser or user by its customers resulting
from the use of the information, recommendations and descriptions contained herein.
The information contained in this manual is subject to change without notice.

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Table of Contents
LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Definitions and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Hazardous High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
CHAPTER 1 — OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CHAPTER 2 — BOARD LAYOUT AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . 2-1
OPTCB Communication Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 — INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Making the Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Bus Terminal Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Bus Biasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
LED Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Installing the OPTCB Communication Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
CHAPTER 4 — COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fieldbus Board Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Siemens FLN Communication Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CHAPTER 5 — SIEMENS FLN (P1) PROTOCOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
P1 Point Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHAPTER 6 — COMMUNICATION BOARD FAULT TRACKING . . . . . . . . . . . . . . . . . . 6-1

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List of Figures
Figure 2-1: OPTCB Communication Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 3-1: Cable Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Figure 3-2: Inserting the Data Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Figure 3-3: Grounding the Communication Cables . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Figure 3-4: Stripping the Communication Cables . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Figure 3-5: Grounding the Communication Cables . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-6: Using Jumper X4 to Set the Bus Termination . . . . . . . . . . . . . . . . . . 3-3
Figure 3-7: Connecting Resistor Biasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-8: LED Indications on the Communication Board . . . . . . . . . . . . . . . . . . 3-5
Figure 4-1: Communication Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
List of Tables
Table 1-1: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Table 2-1: OPTCB Bus Connector Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Table 3-1: Bias Resistor Size vs. Number of Nodes . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Table 3-2: Communication Board Status LED (BS) — YELLOW . . . . . . . . . . . . . . 3-5
Table 3-3: Fieldbus Status LED (FS) — GREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Table 3-4: Installing the OPTCB Communication Board . . . . . . . . . . . . . . . . . . . . 3-6
Table 4-1: Changing the FLN Board Commissioning Parameter Values . . . . . . . 4-1
Table 4-2: Communication Message Indications . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Table 5-1: Analog Inputs (AI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Table 5-2: Analog Outputs (AO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Table 5-3: Binary Inputs (BI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Table 5-4: Binary Outputs (BO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Table 6-1: Communication Board Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Table 6-2: AFD Response to Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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Safety
Definitions and Symbols
WARNING
This symbol indicates high voltage. It calls your attention to items
or operations that could be dangerous to you and other persons
operating this equipment. Read the message and follow the
instructions carefully.
This symbol is the “Safety Alert Symbol.” It occurs with either of
two signal words: CAUTION or WARNING, as described below.
WARNING
Indicates a potentially hazardous situation which, if not avoided,
can result in serious injury or death.
CAUTION
Indicates a potentially hazardous situation which, if not avoided,
can result in minor to moderate injury, or serious damage to the
product. The situation described in the CAUTION may, if not
avoided, lead to serious results. Important safety measures are
described in CAUTION (as well as WARNING).
Hazardous High Voltage
WARNING
Motor control equipment and electronic controllers are connected
to hazardous line voltages. When servicing drives and electronic
controllers, there may be exposed components with housings or
protrusions at or above line potential. Extreme care should be taken
to protect against shock.
Stand on an insulating pad and make it a habit to use only one
hand when checking components. Always work with another
person in case an emergency occurs. Disconnect power before
checking controllers or performing maintenance. Be sure
equipment is properly grounded. Wear safety glasses whenever
working on electronic controllers or rotating machinery.

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Chapter 1 — Overview
Introduction
The HVX9000 from Eaton’s electrical business can be controlled, monitored and
programmed from a host system via the Siemens APOGEE™ FLN (P1) communication
protocols with the addition of the OPTCB RS-485 Communication Option Board kit.
If you purchase your Communication Board Kit separate from the drive, please note that it
must be installed in slot E on the control board of the HVX9000.
Specifications
Table 1-1: Specifications
Item Specification
Communication Board Connections
Interface OPTCB: Pluggable connector (5.08 mm)
Data Transfer Method RS-485, half-duplex
Transfer Cable Twisted pair (1 pair and shield)
Electrical Isolation 500V DC
Communications
Siemens P1 As described in Siemens P1 Protocol Specification
Baud Rate 4800 baud
Addresses 0 to 99
Environment
Ambient Operating Temperature 14 to 131°F (-10 to 55°C)
Storage Temperature -40 to 140°F (-40 to 60°C)
Humidity <95%, non-condensing
Altitude Max. 3280 ft. (1000m)
Vibration 0.5G at 9 to 200 Hz
Safety
Standards Fulfils EN 50178 standard
Certification CE, UL

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Chapter 2 — Board Layout and Connections
The RS-485 Communication Board is connected to the communications bus through a 5-pin
pluggable bus connector (OPTCB board).
Communication with the control board of the drive takes place through the standard interface
board connector shown in Figure 2-1.
OPTCB Communication Board
Figure 2-1: OPTCB Communication Board
Table 2-1: OPTCB Bus Connector Signals
This pin (1) can be used to bypass the cable shield to the next slave.
Jumper X4 is the 120Ωtermination resistor. Set jumper X4 to ON only if
the drive is the last device on the network.
Jumper X1 has no effect on OPTCB board.
Signal Connector Description
NC 1 No connection
VP 2 Supply voltage – plus (5V)
RxD/TxD –N 3 Receive/Transmit data – minus (A)
RxD/TxD –P 4 Receive/Transmit data – plus (B)
DGND 5 Data ground (reference potential for VP)
1
2
3
4
5
X1
Bus
Connector
X4
Jumpers Interface Board
Connector
ON
OFF

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Chapter 3 — Installation
Making the Ground Connection
Grounding by Clamping the Cable to the Drive Frame
This method of grounding is the most effective, and especially recommended when the
distances between the devices are relatively short or if the device is the last device on the
network.
Note: Normally, the option board has already been installed in slot E of the control board. It is
not necessary to detach the whole board to ground the bus cable shield. Just detach
the terminal block.
1. Strip about 2 in. (5 cm) from the cables (shown at the left of Figure 3-1 ), and cut off the
gray cable shield.
Note: Do this for both communication cables, except for the last device.
2. Leave no more than 1/4 in. (1 cm) of each cable outside the terminal block, and strip the
ends of both cables (shown at the right of Figure 3-1 ) to about 0.2 in (0.5 cm) to fit in the
terminals.
Figure 3-1: Cable Stripping
3. Insert the cables into Terminals 3 (Cable A) and 4 (Cable B). See Figure 3-2 .
Figure 3-2: Inserting the Data Cables
AB
345
2
1

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4. Strip the communication cables so they can be secured to the drive frame with the
grounding clamp. See Figure 3-3 .
Figure 3-3: Grounding the Communication Cables
Grounding Only One Point on the Net
In this method of grounding, the shield is connected to ground only at the last device on the
network. Other devices on the network bypass the shield.
1. Strip about 2 in. (5 cm) from the cables and cut off the gray cable shield.
2. Leave no more than 1/4 in. (1 cm) of each cable outside the terminal block, and strip the
ends of both cables to about 0.2 in. (0.5 cm) to fit in the terminals. See Figure 3-4 .
Note: We recommend that you use an Abico connector to fit the shields into the terminal.
Figure 3-4: Stripping the Communication Cables
AB
345
2
1
Shield

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3. Secure the communication cables to the drive frame with the grounding clamp as
shown in Figure 3-5 .
Figure 3-5: Grounding the Communication Cables
Bus Terminal Resistors
If the OPTCB connector is the last device on the network, the bus termination must be set to
ON with Jumper X4. See Figure 3-6 .
Figure 3-6: Using Jumper X4 to Set the Bus Termination
1
2
3
4
5
X1
ON = Terminated: This is the last device on network.
Bus
Connector
Jumpers Interface Board
Connector
X4
device is connected past this device.
OFF = Not Terminated: At least one other network

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Bus Biasing
Bus biasing is required to ensure faultless communication between devices at RS-485 bus.
Bus biasing makes sure that the bus state has proper potential when no one is transmitting.
Without biasing faulty messages can be detected when the bus is in idle state. RS-485 bus
state should be from +0.200 to +7V or -0.200 to -7V. Illegal bus state is from -0.200 to 0.200V.
Table 3-1: Bias Resistor Size vs. Number of Nodes
Failsafe Biasing in OPTCB Option Board
Connect resistor biasing resistors between PIN 2 – PIN 4 and PIN 3 – PIN 5. See Figure 3-7 .
Figure 3-7: Connecting Resistor Biasing
National Semiconductor (www.national.com) has a very good application note, Failsafe
Biasing of Differential Buses (AN-847.PDF), concerning this problem.
Number of Nodes Bias Resistance
2 – 5 1.8k ohm
5 – 10 2.7k ohm
11 – 20 12k ohm
21 – 30 18k ohm
31 – 40 27k ohm
D
ata
-
D
ata
+

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LED Indications
The two LED indicators next to the connector show the present status of the Communication
Board (yellow) and the Fieldbus Module (green). See Figure 3-8 , Table 3-2 and Table 3-3 .
Figure 3-8: LED Indications on the Communication Board
Table 3-2: Communication Board Status LED (BS) — YELLOW
Table 3-3: Fieldbus Status LED (FS) — GREEN
LED is: Meaning:
OFF Option board not activated
ON Option board in initialization state waiting for activation command from
the Adjustable Frequency Drive (AFD)
Blinking fast (once/sec) Option board is activated and in RUN state
Option board is ready for external communication
Blinking slow (once/5 secs) Option board is activated and in FAULT state
Internal fault of option board
LED is: Meaning:
OFF Fieldbus module is waiting for parameters from the AFD
No external communication
ON Fieldbus module is activated
Parameters received and module activated
Module is waiting for messages from the bus
Blinking fast (once/sec) Module is activated and receiving messages from the bus
Blinking slow (once/5 secs) Module is in FAULT state
No messages from Master within the watchdog time
Bus broken, cable loose or Master off-line
1
2
3
4
5
X1
Yellow
Yellow
Green
Green
= RS-485 Board Status
= Fieldbus Status
X6

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Installing the OPTCB Communication Board
Table 3-4: Installing the OPTCB Communication Board
Procedure Illustration
1. Remove the cable cover.
2. Open the cover of the control unit.
3. Install the OPTCB option board in slot E on the control
board of the AFD. Make sure that the grounding plate
(shown below) fits tightly in the clamp.
1
2
3
4
5
X1
Grounding Plate
X4

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Table 3-4: Installing the OPTCB Communication Board, continued
Procedure Illustration
4. Make a sufficiently wide opening for your cable by cutting
the cover grid as wide as necessary.
5. Close the cover of the control unit and the cable cover.

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Chapter 4 — Commissioning
Fieldbus Board Parameters
The RS-485 Communication Board (OPTCB) is commissioned with the control keypad by
giving values to appropriate parameters in the Expander board menu M4.
Expander Board Menu (M4)
The Expander board menu makes it possible for the user (1) to see what expander boards are
connected to the control board, and (2) to view and edit the parameters associated with the
expander board.
Enter the following menu level (G4)with the menu button (right arrow). At this level, you
can browse through slots A to E with the Browser buttons to see which expander boards are
installed. On the bottom line of the display, you also see the number of parameter groups
associated with the board.
If you press the menu button again, you will reach the parameter group level where there
are two groups: Editable parameters and Monitored values. Another press on the menu
button takes you to either of these groups.
Siemens FLN Communication Parameters
To commission the Siemens FLN Communication Board, enter the level P4.5.1.# from the
Expander Board Menu 4. The board can be installed in either slot D (G4.4) or slot E (G4.5). It is
installed in slot E from the factory.
Table 4-1: Changing the FLN Board Commissioning Parameter Values
The SLAVE ADDRESS of every device must be set before connecting to the bus. The SLAVE
ADDRESS must be the same as in the master configuration. The baud rate is automatically
configured for 4800. No adjustment is possible.
1. Review the following drive and fieldbus application parameter settings:
●Check that application HVX9.11 or later is selected.
Application Selection S3.2 = HVX9.11 or later version
Refer to the HVX9000 User Manual for instructions on how to set parameters using
the keypad.
●Check that start source auto is set to network. This allows the user to provide start/
stop commands from the FLN network.
Parameter P1.1.17 = Fieldbus
●Check that reference source auto is set to network. This allows the user to provide
a speed reference from the FLN network.
Parameter P1.1.18 = Fieldbus
●Check that the HOA mode is set to AUTO.
#Name Default Range Description
1Communication
Timeout
10 0 – OFF
1 – 300 s
See Communication Timeout on Page 4-2.

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2. Set the FLN address for the device if desired (default address is 99).
Parameter P1.13.9 = (1 – 99)
The drive is set up for FLN network communication.
For more information about the description of some parameters, see the HVX9000 User
Manual, HVX9.11 or later version.
Communication Timeout
The RS-485 Communication Board initiates a communication error if communication is
broken for as long as defined by the Communication Timeout. Communication Timeout is
disabled when given a 0 value.
Communication Status
To see the present status of the communication board, enter the Communication status page
from the Monitor menu (G7.5.2). See Figure 4-1 and Table 4-2.
Figure 4-1: Communication Status
Table 4-2: Communication Message Indications
Messages Indications
Good messages
0 – 999 Number of messages received without communication errors
Error messages
0 – 64 Number of messages received with CRC or parity errors
Comm. status
Monitor
V1 V1 0.841
Good Message
Error Message