Emotron VFX 2.0 User manual

Emotron VFX/FDU 2.0
Fieldbus Option
Profibus DP, DeviceNet, Modbus/TCP
Instruction manual
English

Document number: 01-3698-01
Edition: r4
Date of release: 2009-09-01
© Copyright Emotron AB 2005 - 2009
Emotron retains the right to change specifications and illustra-
tions in the text, without prior notification. The contents of this
document may not be copied without the explicit permission of
Emotron AB.
Emotron VFX/FDU 2.0 Fieldbus Option
Profibus DP, DeviceNet, Modbus/TCP
Instruction manual – English

H

Emotron AB 01-3698-01r4
Safety
Instruction manual
Read this instruction manual first!
Since this option is a supplementary part of the variable speed drive (VSD), the
user must be acquainted with the original instruction manual of the variable
speed drive. All safety instructions, warnings, etc. as mentioned in this instruc-
tion manual are to be known to the user.
Safety instructions
Read the safety instructions in the instruction manual for the variable speed
drive.
Installation
Installation, commissioning, dismounting, making measurements, etc. on the
variable speed drive may only be carried out by personnel who are technically
qualified for the task. Installation must also be carried out in accordance with
the local standards. Ensure that all necessary safety measures are taken.
Opening the variable speed drive
Always take adequate precautions before opening the variable speed drive, even
though the connections for the control signals and jumpers are isolated from
the mains voltage.
WARNING: Take all necessary safety precautions during
installation and commissioning to prevent personal injuries, e.g.
by an uncontrolled load.
WARNING: Always switch off the mains supply before opening the
variable speed drive and wait at least 5 minutes to allow the
buffer capacitors to discharge.

Emotron AB 01-3698-01r4

Emotron AB 01-3698-01r4 1
Contents
1 Introduction ................................................................................ 5
1.1 Users............................................................................................................ 6
1.2 Before starting ............................................................................................ 6
1.3 Delivery and unpacking.............................................................................. 6
1.4 Checking of contents.................................................................................. 7
1.5 Abbreviations used ..................................................................................... 8
1.6 Byte/Bit numbering .................................................................................... 8
1.7 Further information .................................................................................... 8
2 Fieldbus networks ...................................................................... 9
2.1 General description .................................................................................... 9
2.1.1 State of the fieldbus module .................................................................. 10
2.1.2 Common network problems.................................................................... 11
2.1.3 Troubleshooting using a multimeter ...................................................... 12
2.1.4 Troubleshooting using menu system information ................................. 13
2.1.4.1 Checking internal communication.......................................................... 13
2.1.4.2 Checking external communication ......................................................... 13
2.1.4.3 Solutions to common problems.............................................................. 14
2.2 Recommendations for network installation........................................... 14
2.3 Profibus .................................................................................................... 15
2.3.1 Profibus fieldbus interface and LED indication ..................................... 16
2.3.1.1 Operation LED description ...................................................................... 16
2.3.1.2 Status LED description............................................................................ 16
2.3.1.3 Profibus connector .................................................................................. 17
2.3.2 Cable types............................................................................................... 18
2.3.2.1 Cable type A ............................................................................................. 18
2.3.3 Bus termination ....................................................................................... 19
2.3.3.1 Example.................................................................................................... 19
2.3.4 Address setting ........................................................................................ 20
2.3.5 Baudrate................................................................................................... 20
2.3.6 Profibus Sync/Freeze functionality......................................................... 20
2.4 DeviceNet................................................................................................. 21
2.4.1 DeviceNet fieldbus interface and LED indication.................................. 21

2Emotron AB 01-3698-01r4
2.4.1.1 Network status LED description .............................................................. 21
2.4.1.2 Module status LED description ............................................................... 22
2.4.1.3 DeviceNet connector................................................................................ 22
2.4.2 Cable type ................................................................................................. 22
2.4.3 Bus termination ........................................................................................ 23
2.4.4 Address setting......................................................................................... 23
2.4.5 Baudrate ................................................................................................... 23
2.4.6 Supported CIP Objects ............................................................................. 24
2.4.6.1 Example reading product parameter ...................................................... 25
3 Industrial Ethernet networks .................................................. 27
3.1 General description.................................................................................. 27
3.1.1 History ....................................................................................................... 27
3.1.2 The difference between office Ethernet and Industrial Ethernet.......... 27
3.1.3 General Ethernet menus.......................................................................... 28
3.1.4 Anybus IPconfig ........................................................................................ 30
3.1.5 Web server interface................................................................................ 31
3.2 Recommendations for network installation ........................................... 38
3.3 Modbus/TCP............................................................................................. 39
3.3.1 Modbus/TCP interface and LED indication ............................................ 40
3.3.1.1 Network status LED description .............................................................. 40
3.3.1.2 Module status LED description ............................................................... 40
3.3.1.3 Link/activity LED description................................................................... 41
3.3.1.4 Modbus/TCP connector description ....................................................... 41
3.3.2 Cable type ................................................................................................. 41
3.3.3 Baudrate ................................................................................................... 42
3.3.4 Modbus/TCP protocol description .......................................................... 43
3.3.5 How to convert modbus numbers into starting addresses ................... 45
3.3.6 Read Coil Status ....................................................................................... 45
3.3.7 Read Holding Registers ........................................................................... 46
3.3.8 Read Input Registers................................................................................ 47
3.3.9 Force Single Coil....................................................................................... 48
3.3.10 Write Single Register................................................................................ 49
3.3.11 Force Multiple Coil.................................................................................... 50
3.3.12 Write Multiple Register ............................................................................ 51
3.3.13 Write/Read Multiple Register.................................................................. 52

Emotron AB 01-3698-01r4 3
3.3.14 Exception codes ...................................................................................... 53
3.3.15 Regrouping of registers ........................................................................... 53
3.3.15.1 How to regroup registers......................................................................... 54
3.3.15.2 How to access the DATA of the regrouped registers ............................. 55
3.3.16 Control & Status register for Modbus/TCP ............................................ 56
4 Fieldbus menus ........................................................................ 57
4.1 General communication menus ............................................................. 57
4.2 Status menus........................................................................................... 59
4.3 Quick Setup.............................................................................................. 60
5 Cyclic/Acyclic data .................................................................. 63
5.1 Byte swapping.......................................................................................... 63
5.1.1 Example.................................................................................................... 63
5.2 Cyclic data (process data)....................................................................... 64
5.2.1 PLC configuration of modules/cyclic data ............................................. 64
5.2.1.1 Module configuration Basic mode.......................................................... 66
5.2.1.2 Module configuration Extended mode ................................................... 67
5.2.1.3 Additional configuration of extra process values .................................. 68
5.2.2 Module data mapping ............................................................................. 69
5.2.2.1 Mapping of Basic mode .......................................................................... 70
5.2.2.2 Mapping of the extended mode ............................................................. 73
5.2.2.3 Mapping of additional process values ................................................... 77
5.2.2.4 Other comments ...................................................................................... 78
5.2.3 Replace an old fieldbus option ............................................................... 79
5.3 Acyclic data (parameters) ....................................................................... 79
5.3.1 Fieldbus parameters ............................................................................... 79
5.4 EmoSoftCom — a help tool...................................................................... 80
6. Parameter sets and Trip log lists ............................................ 81
7. Frequently asked questions .................................................... 83
8. Installation................................................................................ 85
8.1 Polarisation of flat cables ....................................................................... 85
8.2 Mechanical mounting.............................................................................. 86
8.3 Mounting the option board ..................................................................... 86
8.4 Inserting the fieldbus module on to the option board .......................... 89

4Emotron AB 01-3698-01r4
8.5 Connecting the network cable................................................................. 89
8.5.1 Installation ................................................................................................ 89
8.5.2 Removal .................................................................................................... 90
8.6 Shielding ................................................................................................... 91

Emotron AB 01-3698-01r4 Introduction 5
1 Introduction
This instruction manual describes the installation and operation of the Fieldbus
option board 2.0, which can be built into the products VFX 2.0 and FDU 2.0.
Further on in this manual we refer to the variable speed drive.
The Fieldbus option allows external equipment to exchange data and to control
the products described in this manual. The Fieldbus option acts as a slave in a
master-slave configuration.
The data and illustrations found in this document are not binding. Emotron
reserves the right to modify our products in line with our policy of continuous
product development. The information in this document is subject to change
without notice and should not be considered as a commitment by Emotron.
There are many applications for this product. Those responsible for the use of
this device must ensure that all necessary steps have been taken to verify that the
application meets all performance and safety requirements including any appli-
cable laws, regulations, codes and standards.
Because this option is a supplementary part of the variable speed drive, the user
must be familiar with the original instruction manual of the VSD. All safety
instructions, warnings, etc. as mentioned in these instruction manuals are to be
known to the user.
The following indications can appear in this manual. Always read these first and
be aware of their content before continuing:
NOTE: Additional information to avoid problems.
CAUTION: Failure to follow these instructions can result in malfunction
or damage to the variable speed drive.
WARNING: Failure to follow these instructions can result in
serious injury to the user in addition to serious damage to the variable
speed drive.
!
Content

6Introduction Emotron AB 01-3698-01r4
1.1 Users
In general, we assume that the user has basic knowledge of communication sys-
tems. This instruction manual is intended for installation, maintenance, service
engineers and programmers
1.2 Before starting
As well as this manual, have the manual for the VSD ready since it contains
additional information not covered here. These product manuals are referred to
at various points through this manual.
This manual contains information on general network troubleshooting for your
convenience. Please note that Emotron cannot support all general questions
regarding your specific network issues/installations if they are not related to the
VSD or fieldbus option.
1.3 Delivery and unpacking
Check for any visible signs of damage. Inform your supplier immediately if any
damage is found. Do not install the option board if damage is found.
If the option board is moved from a cold storage room to the room where it is to
be installed, condensation can form on it. Allow the option board to become
fully acclimatised and wait until any visible condensation has evaporated before
installing it in the VSD.
Content

Emotron AB 01-3698-01r4 Introduction 7
1.4 Checking of contents
Fieldbus modules
Table 1
Pieces Component
1 CD with configuration files
1 Fieldbus module mounted on a circuit board, see below.
1Flatcable
1Mountingmaterial
1Manual
Profibus DP-V1
Modbus/TCP
DeviceNet
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8Introduction Emotron AB 01-3698-01r4
1.5 Abbreviations used
1.6 Byte/Bit numbering
1.7 Further information
Further information about specific fieldbus system can be found on the Inter-
net.
Profibus: www.profibus.com
DeviceNet: www.odva.org
Modbus/TCP: www.modbus-ida.org
Specific information about Emotron options/products and configuration files
can be found at: www.emotron.com.
Table 2
GSD file
Profibus-specific configuration files in ASCII format containing informa-
tion about the node characteristics, i.e. supported baudrate and other
features. GSD=General Station Description
Cyclic data
Information which is sent to and from a node at regular time intervals.
Typically this information includes run/stop, reference and control val-
ues, etc., i.e. information which needs to be updated at all times. Cyclic
data is sometimes denoted as process data.
Acyclic
data
Information which is sent to and from a node at irregular time intervals.
Typically this information includes configuration data, i.e. motor data
setup. There is no need to send this type of information at cyclic inter-
vals since it will not change.
Master Central unit which controls the system, usually a PLC. In a profibus net-
work, a master is also often called “active station”.
Termina-
tion
Method of attenuating the signal at cable ends to avoid reflections. This
is usually done with a simple resistor connection.
PE Protective Earth. Installation point which is connected to the protective
earth point of the mains supply.
IE Industrial Ethernet
VSD Variable Speed Drive
7......... 0 7 ........ 0 7 ........ 0 7 ........ 0
32 10Byte:
Bit:
Content

Emotron AB 01-3698-01r4 Fieldbus networks 9
2 Fieldbus networks
2.1 General description
All fieldbus options available through Emotron are based on an open serial com-
munication standard that enables data exchange between the variable speed
drives (VSD) and a network controller (PLC master).
Advantages of using a serial communication network:
• Geographically distributed systems can be controlled from a central unit
(master)
• Production data can be collected and analysed
• Shorter cable lengths (when compared to using analogue cables for every
node)
• Centralized supervision/diagnostic
• Exchangeability of units when using a network standard
• Modular construction
• Easy to extend network when necessary
• Easy installation (less time needed)
• Documentation of network easy (when compared to analogue signals)
• More robust against interference when using digital signals (resending mes-
sage)
The network controller/master (usually a PLC = programmable logic controller)
polls the slave nodes (e.g. VSD/softstarter), which respond with a telegram over
the network and perform commands sent by the master unit.
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10 Fieldbus networks Emotron AB 01-3698-01r4
2.1.1 State of the fieldbus module
At any given time, the module is considered to be operating in one out of seven
states. The current state of the fieldbus module is presented in VSD menu
[2693].
SETUP
(00h)
NW_INIT
(01h)
WAIT_PROCESS
(02h)
PROCESS_ACTIVE
(04h)
ERROR
(05h)
IDLE
(03h)
EXCEPTION
(07h)
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2.1.2 Common network problems
This section describes how to locate network-related problems in a Profibus net-
work. However, the hints given apply to most standard fieldbus systems.
1. A and B wires crossed somewhere in the network (applies to RS485 physical
interface fieldbus systems).
2. Network not terminated in the ends (of each segment).
3. Incorrect nodes (non-ending nodes) terminated.
4. Cable cut off.
A common method of finding network-related problems is to reduce the net-
work step-by-step until the problem disappears. This can be done by discon-
necting the outgoing profibus cable from a specific node and terminating at this
point.
Ta b l e 3
State no. State name Description
00 SETUP The module is not yet initialised. No exchange of
process data.
01 NW_INIT
The module is currently performing network related
initialisation tasks. No exchange of process data
(ignored).
02 WAIT_PROCESS
The network process data is temporarily inactive
(ignored).This state will trigger a trip/warning if
menu [2641] is not Off. If a Profibus or DeviceNet
bus line is cut off the node will enter this state.
03 IDLE The network is in idle mode (network specific
behaviour).
04 PROCESS_ACTIVE The network process data channel is active, i.e. all
process data is exchanged.
05 ERROR There is at least one serious network error. Process
data will be ignored.
07 EXCEPTION
Network communication is halted due to:
- Invalid network configuration parameter
- Timeout
- etc.
This status is not recoverable, which means that
the module must be restarted (power off - power
on) to be able to exchange network data again.
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12 Fieldbus networks Emotron AB 01-3698-01r4
Furthermore, a simple multimeter can come in handy for measuring the resist-
ance of the cable (checking connection).
The PLC-master system may also provide additional diagnostic information.
Has the correct *.gsd file been installed?
There are also more advanced tools available on the market, so called “network
analysers” which can be used when encountering problems of a more difficult
nature.
2.1.3 Troubleshooting using a multimeter
This section describes how to do simple measurements on a Profibus network.
The technique is basically the same as for other fieldbusses but with different
resistance values in cable/termination (please refer to your standard fieldbus
documentation).
• Check that the resistance between A&B wires (pins 3 and 8 in the D-sub
connector) is approximately 100 ohm. The measured value depends on cor-
rect termination, cable type and total cable length.
• A very low value indicates a short circuit somewhere in the network.
• A Profibus cable has a resistance of approx. 50 ohm/km.
• Check if there is a short circuit between the shield and either the A or B
wire. The resistance should be equal or higher than 10 kohm (but is likely to
be much higher).
• Check if the shield is connected to the chassis and/or PE-din rail. Normally
the resistance should be less than or equal to 10 ohm.
• Check that the A and B wire are not crossed.
NOTE: The resistance measurements must be performed while the network
is powered down.
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Emotron AB 01-3698-01r4 Fieldbus networks 13
2.1.4 Troubleshooting using menu system information
2.1.4.1 Checking internal communication
It is important to check that the internal communication between the control
board and the fieldbus option is working. Consider the following issues:
1. Go through the page 57 in chapter 4 to make sure all settings are correct.
2. Check menu [2696]-[2698] —is any counter continuously increasing? In
this case it indicates a problem with the internal communication between
the control board and the fieldbus module or that no process data has been
configured.
3. Check that the flat cable between the control board and the fieldbus board is
properly connected and polarized.
If all the above is normal, then it is likely that the problem lies outside the VSD.
Continue with the next section “Checking external communication” on
page 13.
2.1.4.2 Checking external communication
1. Check LED status of the fieldbus module —error indication? power on?
2. Check menu [2693] —state of fieldbus module
3. Check menu [2692] —SUP-bit —is the slave node supervised by a master?
4. The VSD must be restarted before the new address setting will take affect,
see note below.
NOTE: The VSD must be restarted before the new setting(s) will be used.
There are two ways of doing so:
1. Soft restart by changing menu [261] to RS232/485 and press Enter.
Then change the setting to Fieldbus and press Enter again. This is valid for
control board software version 4.11 and later, see menu [922]. The VSD will
reboot during approximately 5 seconds. For safety reasons it is only
possible to change menu [261] when the VSD is stopped.
2. Hard restart by switching off the power, wait for the Control Panel to
become unlit, then switch the power back on.
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14 Fieldbus networks Emotron AB 01-3698-01r4
2.1.4.3 Solutions to common problems
2.2 Recommendations for network installation
This section gives general installation recommendations.
• Always build your network so that it is possible to use the highest available
baudrate for the network standard currently in use. This will make your
installation robust and you can easily increase the baudrate in the future
without replacing cables etc.
• Use the recommended cable according to each network standard. Take envi-
ronmental issues into account, such as cables resistant to oil, water, grease,
temperature, UV radiation, etc.
• Avoid drop cables (valid for Profibus networks).
• Always use shielded cables.
• A general recommendation is to connect the cable shield to the PE at every
cable end. Note that this might require an equipotential bonding system.
• Place the network cable as far away from power cables as possible. A distance
of at least 20 cm is recommended.
• When crossing power cables, try doing this at a 90-degree angle. Avoid lay-
ing the network cable in parallel to the power cable.
• Do not twist, stretch or crimp any cables.
• Protect the cable from being damaged, e.g. by using cable channels/
grounded metallic cable racks.
Ta b l e 4
Problem Solution
The VSD does not accept any
cyclic data commands.
Check that the VSD menu [2633] is set to RW
(read/write).
Check the PLC diagnostic messages.
Check menu [2632] and [2634] —cyclic data size.
Is the same mapping used for the PLC master?
The VSD ignores the reference
value sent by the master.
Check menu [2699] —incoming Basic process
data and menu [214] — Ref Control.
The VSD does not start when
given start command.
Check menu [2699] —incoming Basic process
data and menu [215] — Run/Stp Ctrl.
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Emotron AB 01-3698-01r4 Fieldbus networks 15
2.3 Profibus
The profibus protocol is specified by the EN 50170 standard. There are three
main communication profiles within Profibus:
1. Profibus-FMS (Fieldbus Message Specification)
2. Profibus-DP (Decentralised Periphery)
3. Profibus-PA (Process Automation)
The module supplied from Emotron supports Profibus-DP (version 1).
The physical transmission medium of the bus is a twisted pair of cables (accord-
ing to the RS-485 standard). Maximum length is 100-1200 metres (depending
on the baudrate).
Up to 32 nodes can be connected in the same network segment without using
repeaters. With repeaters it is possible to connect up to 127 nodes (including
repeaters and master stations) in the network.
When adding a new node to the network the master needs to be informed of the
network change. This is done by installing a configuration file (*.gsd). This file
contains information about the new slave node’s available functions.
NOTE: Repeaters do not have a station address, but they count towards the
maximum number of stations in each segment.
Content