Ge Ecomagination profibus dp af-650 gp User manual

AF-650 GPTM & AF-600 FPTM

Probus DP

Instruction Manual

The instructions do not claim to cover every single detail or variation in the equipment nor do they provide for every pos-

sible contingency in connection with installation, operation or maintenance.

Should further information be desired or should particular problems arise which are not covered suciently for the pur-

chaser’s purposes, the matter should be referred to the GE company

AF-650 GP and AF-600 FP are trademarks of the General Electric Company.

41 Woodford Avenue

Plainville, CT 06062

www.geelectrical.com/drives

130R0137 *MG11X122* DET-624

Contents

1 Introduction

1-1

Safety Note 1-1

Technical Overview 1-4

Network Topology 1-4

2 How to Install

2-1

Cabling 2-1

EMC Precautions 2-2

Connecting the Network 2-3

3 How to Configure the System

3-1

Configure the PROFIBUS Network 3-1

Configure the Master 3-2

GSD File 3-2

Configure the Adjustable Frequency Drive 3-4

Drive Parameters 3-4

LEDs 3-5

4 How to Control the Adjustable Frequency Drive

4-1

PPO Types 4-1

Process Data 4-3

Reference Handling 4-3

Process Control Operation 4-5

Control Profile 4-5

PROFIdrive Control Profile 4-5

GE Drive Control Profile 4-11

Synchronize and Freeze 4-15

5 How to Access the Parameters

5-1

Parameter Access in General 5-1

DP V1 Parameter Access 5-2

How to Use the DP V1 Features for Parameter Access 5-4

PCV Parameter Access 5-12

6 Parameters

6-1

PROFIBUS-specific Parameter List 6-11

Object and Data Types Supported 6-12

7 Application Examples

7-1

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E.g.: Process Data with PPO Type 6 7-1

E.g.: Control Word Network using PPO Type 7-3

E.g.: Status Word Network using PPO Type 7-4

E.g.: PLC Programming 7-5

8 Troubleshooting

8-1

Diagnostics 8-1

Troubleshooting 8-1

LED Status 8-1

No Communication with the Drive 8-2

Warning 34 Appears even though Communication is Established 8-3

Drive Will Not Respond to Control Signals 8-3

Alarm and Warning Words 8-6

Fault Messages via DP Diagnostics 8-7

Extended Diagnostics 8-7

9 Warnings and Alarms

9-1

Status Messages 9-1

Warnings/Alarm Messages 9-1

Alarm List 9-2

10 Index

10-1

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1Introduction

1.1.1 Copyright, Limitation of Liability and Revision Rights

This publication contains information proprietary to GE. By accepting and using this manual the user agrees that the information contained herein will be used

solely for operating equipment from GE or equipment from other vendors provided that such equipment is intended for communication with GE equipment

over a PROFIBUS serial communication link. This publication is protected under the Copyright laws.

GE does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical, hardware

or software environment.

Although GE has tested and reviewed the documentation within this manual, GE makes no warranty or representation, either express or implied, with respect

to this documentation, including its quality, performance, or fitness for a particular purpose.

In no event shall GE be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use information con-

tained in this manual, even if advised of the possibility of such damages. In particular, GE is not responsible for any costs including but not limited to those

incurred as a result of lost profits or revenue, loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute these, or any claims

by third parties.

GE reserves the right to revise this publication at any time and to make changes in its contents without prior notice or any obligation to notify previous users of

such revisions or changes.

1.2.1 Safety Note

The voltage of the adjustable frequency drive is dangerous whenever connected to line power. Incorrect installation of the motor, adjusta-

ble frequency drive or network may cause damage to the equipment, serious personal injury or death. Consequently, the instructions in this

manual, as well as national and local rules and safety regulations, must be complied with.

1.2.2 Safety Regulations

1. The adjustable frequency drive must be disconnected from line power if repair work is to be carried out. Make sure that the line power supply has

been disconnected and that the necessary time has passed before removing motor and line power plugs.

2. The [OFF] key on the control panel of the adjustable frequency drive does not disconnect the equipment from line power and is thus not to be used as

a safety switch. 3. Correct protective grounding of the equipment must be established, the user must be protected against supply voltage, and the

motor must be protected against overload in accordance with applicable national and local regulations.

3. Correct protective grounding of the equipment must be established, the user must be protected against supply voltage, and the motor must be pro-

tected against overload in accordance with applicable national and local regulations.

4. The ground leakage currents are higher than 3.5 mA.

5. Protection against motor overload is not included in the factory setting. If this function is desired, set F-10 Electronic Overload to data value Electronic

Overload trip or data value Electronic Overload warning. Note: The function is initialized at 1.16 x rated motor current and rated motor frequency. For

the North American market: The Electronic Overload functions provide class 20 motor overload protection in accordance with NEC.

6. Do not remove the plugs for the motor and line power supply while the adjustable frequency drive is connected to line power. Make sure that the line

power supply has been disconnected and that the necessary time has passed before removing motor and line power plugs.

7. Please note that the adjustable frequency drive has more voltage inputs than L1, L2 and L3 when load sharing (linking of DC intermediate circuit) and

external 24 V DC have been installed. Make sure that all voltage inputs have been disconnected and that the necessary time has passed before

commencing repair work.

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1.2.3 Warning Against Unintended Start

1. The motor can be brought to a stop by means of digital commands, network commands, references or a local stop, while the adjustable frequency

drive is connected to line power. If personal safety considerations make it necessary to ensure that no unintended start occurs, these stop functions

are not sufficient.

2. While parameters are being changed, the motor may start. Consequently, the Off key on the keypad must always be activated; following which data

can be modified.

3. A motor that has been stopped may start if faults occur in the electronics of the adjustable frequency drive, or if a temporary overload or a fault in

the supply line power or the motor connection ceases.

1.2.4 Warning

Touching the electrical parts may be fatal - even after the equipment has been disconnected from line power.

Also make sure that other voltage inputs have been disconnected, such as an external 24V DC using option module OPC24VPS,, load sharing (linkage of DC

intermediate circuit), as well as the motor connection for kinetic backup.

Please refer to the AF-650 GP or AF-600 FP Drive Instruction Manual for further safety guidelines.

1.3 About this Manual

First time users can obtain the most essential information for quick installation and set-up in these chapters:

Introduction

How to Install

How to Configure the System

Application Examples

For more detailed information including the full range of set-up options and diagnostics tools please refer to the chapters:

How to Control the Adjustable Frequency Drive

How to Access the Parameters

Parameters

Troubleshooting

1.4 About PROFIBUS

PROFIBUS is standardized in the international standards IEC 61158 and IEC 61784, and supported by the member companies of the PROFIBUS International

user community.

PROFIBUS International (PI) is the umbrella organization for all Regional PROFIBUS Associations (RPA) worldwide. PI has engaged PNO (PROFIBUS Nutzerorgani-

sation, e. V.), Germany, a non-profit organization based in Karlsruhe, Germany, to establish technical committees and working groups in order to define and

maintain the open and vendor-independent PROFIBUS technology. Any member of PROFIBUS International may take an active part in maintenance and further

development of the PROFIBUS technology. This guarantees openness and vendor independence of the PROFIBUS technology.

For access to the vast quantity of PROFIBUS literature including information and downloads for PROFIBUS DP and the PROFIdrive profile, please refer to

www.profibus.com.

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1.5 About PROFIBUS DP V1

By operating the adjustable frequency drive via a network you can reduce the capital cost of your system, communicate faster and more efficiently, and enjoy

an easier user interface.

Using PROFIBUS DP V1 also guarantees you a product which has wide compatibility, a high level of availability and support, and which will be compatible with

future versions. 10.

With the DCT 10 Drive Control Tool software, you can control and configure your system simultaneously, and monitor the entire system more effectively for

faster diagnostics, and better preventive maintenance. Simplify commissioning, maintenance and documentation using DCT 10 Drive Control Tool software.

Features of PROFIBUS DP V1:

Cost savings

• PROFIBUS DP V1 permits very effective use of PLC I/O capacity, in effect, expanding the volume capacity of your existing PLC by up to two-thirds.

Fast and efficient communication

• short network cycle times

• improved network efficiency

Easy to use

• transparent installation, diagnostics and parameterization

Flexibility and compatibility

• Two different state machines can be selected: PROFIdrive profile or GE Drive profile

• Communication using PROFIBUS DP V1, Master Class 1 and Master Class 2

Future-proof investment

• Downward compatibility: New protocol extensions retain all the functions of the previous versions

• Continuous development of new application-oriented profiles

• Wide product availability

• Intelligent base for future technologies such as OPC, FDT/DTM, PROFINET

Technical features:

• Network timeout reaction

•PLC/CPUstopreaction

• Eight PPO types available

• Numerous relevant process data (PCD) types available

• Automatic detection of baud rate and PPO type

• Extended diagnostics available

• Alarms and warnings available as text messages within the PLC

• Equidistant network cycle time configurable in PLC system

• Improved network efficiency, since the cyclic parameter channel is no longer required

• Very short network cycle times compared to industrial ethernet

• Backwards compatibility with DP

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Features of DCT 10 Drive Control Tool software:

• Project-oriented PC tool, one tool for all AF-6 Series Drives

• Links to all Windows applications possible

• Supports Siemens CPs 5511 (PCMCIA) and 5611 (PCI card), for PROFIBUS DP V1 Master Class 2 connection

• Support of standard interfaces: COMx, USB, RS232 (FLUX)

• Siemens PG / Field PGs already have the necessary hardware

• View is highly configurable

1.6 Technical Overview

1.6.1 Network Topology

Single master

-PLC communicates with messages of constant length

-Fits time-critical requirements

-Cyclical transmission via PPO types

-Extended diagnostics

1.1: PROFIBUS DP V0

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1.6.2 Network Topology

Multiple master

Features of a Master Class 1 connection

-Cyclical data exchange (DP V0)

-Acyclical read/write on parameters

-Extended diagnostics

The acyclical connection is fixed, and cannot be changed during operation.

Features of a Master Class 2 connection:

-Initiate / Abort acyclical connection

-Acyclical read/write on parameters

The acyclical connection can be established (Initiate) or removed (Abort) dy-

namically even when a Master Class 1 is active on the network. The DP V1

acyclical connection can be used for general parameter access as an alter-

native to the PCV parameter channel.

1.2: PROFIBUS DP V1

The PROFIBUS DP extension DP V1 permits acyclical as well as cyclical data communication. This feature can be used by a DP Master Class 1 (e.g., PLC), as well

as a DP Master Class 2 (e.g., PC tool).

1.7 Assumptions

This manual assumes you are using the AF-6 Series Drives Profibus DP Communications Module in conjunction with an AF-650 GP or AF-600 FP drive. It is also

assumed that your master is a PLC or PC equipped with a serial communication card supporting all the PROFIBUS communication services required by your

application, and that all requirements stipulated in the PROFIBUS standard, as well as those set up in the PROFIBUS Variable Speed Drive Profile and its compa-

ny-specific implementation PROFIdrive, as well as those pertaining to the AF-6 Series Drive are strictly observed as well as all limitations therein fully respected.

1.8 Hardware

This Instruction Manual refers to the Profibus network Model No. OPCPDP.

The Profibus Option will be identified as: OPCPDP Profibus DP V1 in ID-60 Option Mounted.

1.9 Background Knowledge

The Profibus DP Communications Module is designed to communicate with any master complying with the PROFIBUS standard. Familiarity with the PC or PLC

you intend to use as a master in your system is assumed. Issues regarding hardware or software produced by other manufacturers are beyond the scope of

this manual, and are not the responsibility of GE.

If you have questions regarding set-up of master-to-master communication, or communication to a non-GE slave, please consult the appropriate manuals.

1.10 Available Literature

For additional AF-6 Series Drives information please visit www.geelectrical.com/drives.

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1.11 Abbreviations

ACI Acyclical Control Interval

AOC Application Orientated Controller

CAN Controller Area Network

CTW Control Word

DP Distributed Periphery

DU Data Unit

EEPROM Electrical Erasable Programmable Read Only Memory

EIA Electronic Industries Alliance: Specifier of the EIA Standard RS 485-A

EMC Electromagnetic Compatibility

FDT Field Device Tool

IND Sub index

ISO International Standards Organization

LCD Liquid Crystal Display

LED Light Emitting Diode

MAV Main Actual Value

MC1 Master Class 1

MC2 Master Class 2

MOC Motion Orientated Controller

MRV Main Reference Value

NDL Network Data Link Layer

PB PROFIBUS

PC Personal Computer

PCD Process Data

PCA Parameter Characteristics

PCV Parameter-Characteristics-Value

PDU Protocol Data Unit

PLC Programmable Logic Control

PNU Parameter Number

PPO Parameter-Process Data

PVA Parameter Value

RC Request/Response Characteristics

SAP Service Access Point

SMP Spontaneous Message

STW Status Word

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2 How to Install

2.1 Cabling

2.1.1 Cable Lengths and Number of Codes

The maximum cable length allowable in one segment is dependent on the transmission speed. The total cable length includes drop cables if any. A drop cable

is the connection from the main network cable to each node if a T-connection is used instead of permissible cable length and maximum number of nodes/

adjustable frequency drives with 1, 2, 3 and 4 network segments.

Drop cable connection (i.e., T-connection) beyond the cable lengths indicated is not recommended, due to the increased risk of reflection occurring. Instead, GE

recommends direct connection of the adjustable frequency drive.

Note that a repeater is a node in both of the two segments it connects. The number of adjustable frequency drives is based on a single master system. If there

are two or more masters (e.g., PC tools), the number of adjustable frequency drives must be reduced correspondingly.

Maximum total network cable length:

Transmission speed 1 segment:

32 nodes

(31 drives)

[m]

2 segments:

64 nodes

(1 repeater, 61 drives)

[m]

3 segments:

96 nodes

(2 repeaters, 91 drives)

[m]

4 segments:

128 nodes

(3 repeaters, 121 drives)

[m]

9.6–187.5 kBaud 1000 2000 3000 4000

500 kBaud 400 800 1200 1600

1.5 Mbaud 200 400 600 800

3–12 Mbaud 100 200 300 400

Total drop cable length limit per segment: Transmission speed Max. drop cable length per

segment

[m]

9.6–93.75 kBaud 96

187.5 kBaud 75

500 kBaud 30

1.5 Mbaud 10

3–12 Mbaud None

The length statements in the tables above are valid for network cable with the following properties:

-Impedance: 135 to 165 ohm at a measuring frequency from 3 to 20 MHz

-Resistance: <110 ohm/km

-Capacitance: <30 pF/m

-Damping: max. 9 dB over the whole wire length

-Cross-section: max. 0.00053 in2 [0.34 mm2], corresponding to AWG 22

-Cable type: twisted in pairs, 1 x 2, or 2 x 2, or 1 x 4 wires

-Shielding: Copper-braided shield or braided shield and foil shield

Use of the same cable type throughout the entire network is recommended to avoid impedance mismatch.

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The numbers on the following diagram indicate the maximum number of stations in each segment. They are not the station addresses, as each station in the

network must have a unique address.

2.1.2 EMC Precautions

The following EMC precautions are recommended to achieve interference-free operation of the PROFIBUS network. Additional EMC information is available in

the AF-6 series Instruction Manual and Design Guides

NOTE

Ensure compliance with relevant national and local regulations, for example in protective ground connection.

2.1.3 Connection of the Cable Shield

The shield of the PROFIBUS cable must always be connected to ground at both ends, meaning the shield must be connected to ground in all stations connec-

ted to the PROFIBUS network. It is very important to have a low impedance ground connection of the shield, also at high frequencies. This can be obtained by

connecting the surface of the shield to ground, for example by means of a cable clamp or a conductive cable connector. The adjustable frequency drive has

various clamps and brackets to enable a proper ground connection of the PROFIBUS cable shield. The shield connection is shown in the section Connecting the

Network.

2.1.4 Ground Connection

It is important that all stations connected to the PROFIBUS network are connected to the same ground potential. The ground connection must have a low HF

(high frequency) impedance. This can be achieved by connecting a large surface area of the cabinet to ground, for example, by mounting the adjustable fre-

quency drive on a conductive rear plate. Particularly when there are long distances between the stations in a PROFIBUS network, it can be necessary to use

additional potential equalizing cables, connecting the individual stations to the same ground potential.

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2.1.5 Cable Routing

The PROFIBUS communication cable must be kept away from motor and brake resistor cables to avoid coupling of high frequency noise from one cable to the

other. Normally a distance of 8 in [200 mm] is sufficient, but maintaining the greatest possible distance between cables is generally recommended, especially

where cables run in parallel over long distances.

If the PROFIBUS cable must cross a motor cable or brake resistor cable, the cables must cross at an angle of 90°.

2.1.6 Connecting the Network

Proper termination of the network is essential. A mismatch of impedance

may result in reflections on the line that will corrupt data transmission.

-The Profibus DP Communications Module has a suitable termina-

tion, activated by switch 1 located on the Profibus option. The

switches must be on to terminate the network. The factory setting

is off.

-Nodes at the physical ends of each segment must be terminated.

-When power to the Profibus DP Communications Module is down,

please note that the termination is still active, although not func-

tional.

-Most masters and repeaters are equipped with their own termi-

nation.

-If an external termination circuit consisting of three resistors is

connected to the network, a 5 V DC power supply must be used.

Terminal 66 and 67 can be used for this.

-The CS pin on the Profibus connector is Control Select. When op-

tion goes into active state and sends a message, the CS pin goes

high (+5 Volts). This can be used to control optical transmitters etc.

or for triggering measurement equipment like an oscilloscope.

-D-sub 9 connector.

If desired, a D-sub 9 adaptor can be added as an option.

Note: If the D-sub 9 adaptor is used, please be aware that the ter-

mination switch on the Profibus option is set to OFF, to avoid dou-

ble termination, as the Profibus D-sub 9 connector also features a

termination switch.

62 = RxD/TxD-P red cable (Siemens B)

63 = RxD/TxD-N green cable (Siemens A)

66 and 67 are for use with external terminator resistor only

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2.2 How to Install the Profibus DP Communications Module in Drive

To install the module in the drive you will need:

-The Profibus DP Communications Module (OPCPDP)

-Network option adaptor frame for the AF-6 Series drives.. This frame is deeper than the standard frame, to allow space for the network option be-

neath

-Cable holders

Instructions:

-Remove the keypad from the adjustable frequency drive

-Remove the frame located beneath and discard

-Push the module into place. Two positions are possible, with cable terminal facing either up or down. The cable up position is often most suitable

when several adjustable frequency drives are installed side by side in a rack, as this position permits shorter cable lengths

-Push the network option adaptor frame into place

-Replace the keypad. - Attach cable

-Fasten the cable in place using cable holders

-The AF-6 Series Drives top surfaces have pre-bored threaded holes for attaching the cable holders to the unit

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3 How to Configure the System

3.1 Configure the PROFIBUS Network

All PROFIBUS stations that are connected to the same network must have a unique station address.

The PROFIBUS address of the adjustable frequency drive can be selected via:

-Hardware switches

-PB-18 Node Address

-The PROFIBUS command SSA Set Station Address

3.1.1 Setting the PROFIBUS Address using the Hardware Switches

Using the hardware switches, it is possible to select an address range from 0 to 125 (factory setting 127) according to the table below:

Switch 8 7 6 5 4 3 2 1

Address value Not used +64 +32 +16 +8 +4 +2 +1

E.g., address 5 Not used OFF OFF OFF OFF ON OFF ON

E.g., address 35 Not used OFF ON OFF OFF OFF ON ON

E.g., address 82 Not used ON OFF ON OFF OFF ON OFF

NOTE

Switch off the power supply before changing the hardware switches.

The address change will come into effect at the next power-up, and can be

read in PB-18 Node Address.

Note the location and sequence of the hardware switches as illustrated in

the figure opposite.

Setting the PROFIBUS Address via PB-18 Node Address:

Setting the address via PB-18 Node Address or the Profibus SSA command is possible, if the hardware switches are set to 126 or 127 (factory switch setting).

The address change will come into effect at the next power-up.

Setting the PROFIBUS Address with the Set Station Address Command:

Setting the address via the "Set Station Address" command is possible, if the hardware switch is set to 126 or 127 (factory switch setting). Using the "Set Station

Address" command, it is possible to lock the programmed address, which makes it impossible to change the address using this command. The address setting

can be unlocked by changing the PB-18 Node Address or the address switch, followed by a power cycle. A new address is effective immediately after the "Set

Station Address" command.

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3.2 Configure the Master

3.2.1 GSD File

In order to configure a PROFIBUS Master, the configuration tool needs a GSD file for each type of slave on the network. The GSD file is a PROFIBUS DP standard

text file containing the necessary communications set-up data for a slave. Download the GSD file for the AF-6 Series drives at www.geelectrical.com/drives.

The first step in configuration of the PROFIBUS master is to import the GSD

file in the configuration tool. The steps outlined below show how to add a

new GSD file to the Simatic Manager software tool. For each drive series, a

GSD file is typically imported once only, following the initial installation of

the software tool.

Using the browser for the GSD file, choose to install all files, which will mean

that both a GSD file and a bitmap for the device will be imported into the

hardware catalog.

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The AF-650 GP GSD file is now imported and will be accessible via the fol-

lowing path in the hardware catalog:

Open a project, set up the hardware and add a PROFIBUS master system.

Select AF-6 Series then drag and drop it onto the PROFIBUS in the hardware

diagram.

A window for the address of the AF-6 Series now appears. Select the ad-

dress from the scroll-down list. Note that this address setting must match

the previous address setting in PB-18 Node Address.

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The next step is to set up the peripheral input and output data. Data set-up

in the peripheral area is transmitted cyclically via PPO types. In the example

below, a PPO type 6 Word consistent is dragged and dropped to the first

slot.

See the PPO types section in How to Control the Adjustable Frequency Drive

for more information.

The configuration tool automatically assigns addresses in the peripheral address area. In this example, the input and output area have the following configura-

tion:

PPO type 6:

PCD word number 1 2 3 4

Input address 256-257 258-259 260-261 262-263

Set-up STW MAV Par. PB-16.2 Par. PB-16.3

3.1: PCD read (Drive to PLC)

PCD word number 1 2 3 4

Output address 256-257 258-259 260-261 262-263

Set-up CTW MRV Par. PB-15.2 Par. PB-15.3

3.2: PCD write (PLC to Drive)

For Profibus SW version 2.x and higher, auto-configuration of process data is supported. This feature makes it possible to configure the process data

( PB-15 PCD Write Configuration and PB-16 PCD Read Configuration) from the PLC/Master. To use Autoconfig, make sure the feature under DP slave Properties

is enabled.

NOTE

DP V1 diagnostics is supported for Profibus SW version 2 and higher. This means that the default setting of the Profibus option is DP V1 diagnostics. If DP V0

diagnostics are required, the setting under DP slave Properties must be changed

Download the configuration file to the PLC. The PROFIBUS system should be able to go online and it will start to exchange data when the PLC is set to run

mode.

3.3 Configure the Adjustable Frequency Drive

3.3.1 Drive Parameters

Pay particular attention to the following parameters when configuring the adjustable frequency drive with a PROFIBUS interface.

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• K-40 [Hand] Button on Keypad. If the Hand button on the adjustable frequency drive is activated, control of the drive via the PROFIBUS interface is

disabled.

• After an initial power-up, the adjustable frequency drive will automatically detect whether a network option is installed in slot A, and set O-02 Control

Word Source to [Option A]. If an option is added or changed in or removed from an already commissioned drive, it will not change O-02 Control Word

Source but enter trip mode, and the drive will display an error.

• O-10 Control Word Profile. Choose between the GE Drive Profile and the PROFIdrive profile

• O-50 Coasting Select to O-56 Preset Reference Select. Selection of how to gate PROFIBUS control commands with digital input command of the

control module.

NOTE

When O-01 Control Site is set to [2] Control word only, then the settings in O-50 Coasting Select to O-56 Preset Reference Select will be overruled, and all act

on bus control.