Lenze C520 Guide

Controller
c520
Commissioning | EN

Contents
1 About this document 7
1.1 Document descripon 7
1.2 Further documents 7
1.3 Notaons and convenons 8
2 Safety instrucons 9
2.1 Basic safety instrucons 9
2.2 Applicaon as directed 9
2.3 Residual hazards 10
3 Product informaon 12
3.1 Idencaon of the products 12
3.2 Features 12
3.3 SD card 12
3.4 Backplane bus 13
3.5 Licence informaon 13
4 Mechanical installaon 14
4.1 Mounng the controller 14
5 Commissioning 15
5.1 Installaon of »PLC Designer« 15
5.2 Commissioning 15
5.3 Connect controller and Engineering PC 16
5.4 Set IP address on the PC 16
5.5 Start controller 17
5.6 Access to SD card 18
5.7 Create PLC program 19
5.8 Create task 20
5.9 Compile PLC program code 20
5.10 Establish connecon between controller and »PLC Designer« 20
5.11 Log in to the controller (load conguraon) 21
5.12 Parameterize controller 22
5.12.1 General informaon on parameter seng 22
5.12.1.1 Addressing of the parameters 22
5.12.1.2 Structure of the parameter descripons 22
5.12.2 Saving the parameter sengs 23
5.12.3 Reset parameters to default 23
5.13 Start PLC program 24
5.14 Generate boot applicaon 24
Contents
3

6 Device sengs 25
6.1 Device name 25
6.2 Host name 25
6.3 Engineering port 26
6.4 Name server addresses 26
6.5 Time 27
6.5.1 NTP server addresses 28
6.6 Device commands 29
6.6.1 Save parameter sengs 30
6.6.2 Reset parameters to default 30
6.6.3 Restart device 31
6.6.4 Start/stop applicaon 31
6.6.5 Load boot project 32
6.6.6 Delete logbook 32
6.6.7 Export logbook 32
6.6.8 Delete log les 33
7Congure engineering port 34
7.1 Conguraon via le 35
7.2 Automac conguraon via parameters 35
7.3 Manual conguraon via parameters 35
Contents
4

8Conguring the network 36
8.1 EtherCAT 37
8.1.1 EtherCAT state machine 38
8.1.2 Addressing of the slaves 40
8.1.3 Commissioning 41
8.1.4 Determine the physical EtherCAT conguraon (network scan) 42
8.1.5 Edit EtherCAT I/O mapping 45
8.1.5.1 Set PDO mapping 45
8.1.5.2 Acvate PDO mapping 45
8.1.6 Restart network 46
8.1.7 Parameter data transfer 46
8.1.8 Diagnoscs 47
8.1.8.1 EtherCAT master diagnoscs 47
8.1.9 Error scenarios 54
8.1.9.1 "Pre-Operaonal" EtherCAT state is not achieved 54
8.1.9.2 "Operaonal" EtherCAT state is not achieved 55
8.1.9.3 A slave does not accept a cyclic frame 55
8.1.9.4 The sync manager conguraon is invalid 55
8.1.9.5 The I/O conguraon is invalid 55
8.1.9.6 Error during process data transfer 55
8.1.9.7 The network cable is not connected. 56
8.1.9.8 A sent frame is not returned to the master 56
8.1.9.9 The output shas make a cracking sound 56
8.1.9.10 The drive shas do not rotate 57
8.1.10 Advanced conguraon 57
8.1.10.1 Device idencaon 57
8.1.10.2 Synchronisaon with "distributed clocks" (DC) 59
8.1.10.3 Set DC synchronizaon 61
8.1.11 Modular machine conguraon 64
8.1.11.1 Behavior of the EtherCAT master 64
8.1.11.2 Mandatory slaves/Oponal slaves 65
8.1.11.3 Conguraon les 66
8.1.11.4 Address assignment 67
8.1.11.5 Error messages 68
8.2 PROFINET 70
8.2.1 Commissioning 72
8.2.1.1 Restarng or stopping the communicaon 72
8.2.1.2 Sengs in the Siemens »TIA Portal« 73
8.2.1.3 Device descripon le 73
8.2.2 Basic seng and opons 74
8.2.2.1 Staon name and IP conguraon 74
8.2.2.2 Suppress diagnosc messages to the IO controller 75
8.2.3 Process data transfer 75
8.2.4 Parameter data transfer 76
8.2.5 Monitoring 77
8.2.6 Diagnoscs 78
8.2.6.1 LED status display 78
8.2.6.2 Informaon on the network 78
Contents
5

9 Device funcons 80
9.1 Device idencaon 80
9.2 Opcal device idencaon 81
9.3 Switch-o behavior 82
9.3.1 Retain variables and persistent variables 82
9.4 Reset controller 83
9.5 Back up and restore data 84
9.5.1 Back up data 85
9.5.2 Restore data 86
9.6 Update rmware 88
10 Replace controller 90
10.1 Dismount controller 91
10.2 Install new controller 92
10.3 Reuse retain data 92
11 Diagnoscs and fault eliminaon 93
11.1 LED status display 93
11.2 Logbook 94
11.3 Diagnosc parameters 95
11.3.1 PLC diagnoscs 95
11.3.2 Network diagnoscs 96
11.3.3 Service life diagnoscs 97
11.4 Error handling 97
12 Appendix 98
12.1 Parameter aribute list 98
Contents
6

1 About this document
These Instrucons apply to the c520 controller.
If you commission a controller together with other devices (e. g. I/O system, inverter, other
network components), please observe the documentaon for the other devices in the
automaon system as well.
WARNING!
Read this documentaon carefully before starng any work.
▶Please observe the safety instrucons!
1.1 Document descripon
This documentaon is valid up to rmware version:
Firmware version Soware data version Date
V_1_4_0 V_1_4_0_001 2020-03-15
1.2 Further documents
For certain tasks, informaon is available in addional documents.
Document Contents/topics
Conguraon document Basic informaon on conguring and ordering the product
"Funconal safety" conguraon document Basic informaon on conguring the "funconal safety" of the product
Mounng instrucons Basic informaon on installing the product
Commissioning document Basic informaon on commissioning the product
Lenze online help Basic and addional informaon on using Lenze Engineering tools to commission the product,
congure its network and diagnose it.
For certain tasks, informaon is available in other media.
Form Contents/topics
Engineering Tools For commissioning
AKB arcles Addional technical informaon for users in the Applicaon Knowledge Base
CAD data Download in dierent formats from the EASY Product Finder
EPLAN macros Project planning, documentaon and management of projects for EPLAN P8.
These media can be found here: Lenze.com
A detailed descripon of the EtherCAT modules can be found on the Internet:
www.Lenze.com à Downloads
Informaon and tools with regard to the Lenze products can be found on the
Internet: www.Lenze.com à Downloads
About this document
Document descripon
7

1.3 Notaons and convenons
Convenons are used in this document to disnguish between dierent types of informaon.
Numeric notaon
Decimal separator Point Generally shown as a decimal point.
Example: 1 234.56
Warnings
UL Warnings UL Are used in English and French.
UR warnings UR
Text
Engineering Tools " " Soware
Example: "Engineer", "EASY Starter"
Icons
Page reference ¶Reference to another page with addional informaon.
Example: ¶ 16 = see page 16
Documentaon reference ,Reference to other documentaon with addional informaon.
Example: , EDKxxx = see documentaon EDKxxx
Layout of the safety instrucons
DANGER!
Indicates an extremely hazardous situaon. Failure to comply with this instrucon will result
in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situaon. Failure to comply with this instrucon may result
in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situaon. Failure to comply with this instrucon may result in slight to
medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instrucon may result in material
damage.
About this document
Notaons and convenons
8

2 Safety instrucons
Disregarding the following basic safety measures and safety informaon may lead to severe
personal injury and damage to property!
Observe all specicaons of the corresponding documentaon supplied. This is the
precondion for safe and trouble-free operaon and for obtaining the product features
specied.
Please observe the specic safety informaon in the other secons!
2.1 Basic safety instrucons
Product
•The product must only be used as directed.
•Never commission the product in the event of visible damage.
•The product must never be technically modied.
•Never commission the product before assembly has been completed.
•The product must never be operated without required covers.
•Connect/disconnect all pluggable terminals only in de-energized condion.
•Only remove the product from the installaon in the deenergized state.
Personnel
Only qualied and skilled personnel are allowed to work with the product. IEC 60364 and/or
CENELEC HD 384 dene the qualicaons of these persons as follows:
•They are familiar with the installaon, mounng, commissioning, and operaon of the
product.
•They possess the appropriate qualicaons for their tasks.
•They are familiar with all regulaons for the prevenon of accidents, direcves, and laws
applicable at the locaon and are able to apply them.
Product
The product must never be technically modied!
If you carry out any technical modicaons or alteraons that are impermissible, all your
warranty claims will become void and the product liability will be excluded!
Device protecon
•The maximum test voltage for insulaon tests between a control potenal of 24 V and PE
must not exceed 110 V DC (EN 61800−5−1).
2.2 Applicaon as directed
The product is a piece of electrical equipment. The product is solely suited to be installed in
control cabinets or similar closed electrical operang areas, and to implement control
concepts, operaonal concepts, or to represent informaon in customary industrial and
commercial areas.
For the purpose of prevenng injury to persons and damage to material assets, higher-level
safety systems have to be used!
Safety instrucons
Basic safety instrucons
9

2.3 Residual hazards
Even if notes given are taken into consideraon and protecve measures are implemented,
the occurrence of residual risks cannot be fully prevented.
The user must take the residual hazards menoned into consideraon in the risk assessment
for his/her machine/system.
If the above is disregarded, this can lead to severe injuries to persons and damage to
property!
Product
Observe the warning labels on the product!
Dangerous electrical voltage:
Before working on the product, make sure there is no voltage applied to the power terminals!
Aer mains disconnecon, the power terminals will sll carry the hazardous electrical voltage for the me given next to the
symbol!
Electrostac sensive devices:
Before working on the product, the sta must ensure to be free of electrostac charge!
High leakage current:
Carry out xed installaon and PE connecon in compliance with:
EN 61800−5−1 / EN 60204−1
Hot surface:
Use personal protecve equipment or wait unl the device has cooled down!
WARNING!
Dangerous electrical voltage
Error on device leads to overvoltage in the system.
▶For a voltage supply with 24 V DC (± 25 %), use a safely separated power supply unit
according to the applicable SELV/PELV requirements.
▶All components connected to USB and RJ45 must be electrically isolated from the mains
according to class III.
NOTICE
Short circuit in the device due to a missing cover.
Destrucon of the device.
▶Close the modules with the contact cover.
NOTICE
Incorrect arrangement of the I/O modules.
Malfuncon of the device.
▶Arrange the modules from le to right on the device.
▶Start with a power supply module or an I/O bus coupler.
Safety instrucons
Residual hazards
10

NOTICE
Unstable LAN connecon due to the use of incorrect cable types.
The LAN connecon may be interrupted.
▶Exclusively use cables of the CAT5-S/FTP type or beer.
▶The unit is to be connected only to internal Ethernet networks without exing a facility and
being subjected to TNVs.
NOTICE
High input voltage at the device.
Destrucon of the device.
▶Observe maximum permissible input voltage.
▶Fuse device at the input against too high input voltage.
NOTICE
Short circuit at the device due to electrostac discharge.
Destrucon of the device.
▶The personnel must be free of electrostac charge prior to working on the device.
NOTICE
Free spaces on the backplane bus.
Malfuncon on the backplane bus due to free spaces between the modules.
▶Connect the modules directly in succession.
NOTICE
Short circuit in the device due to incorrect handling.
Destrucon of the device.
▶Only plug in and remove the controller and modules of the I/O system 1000 when the
supply voltage is switched o.
Safety instrucons
Residual hazards
11

3 Product informaon
3.1 Idencaon of the products
Each device is provided with a nameplate containing the device data. Detailed informaon
about the nameplate data can be found in the product catalog.
3.2 Features
The following gure provides an overview of the elements and connecons on the device.
Posion, size and appearance of elements and connecons may vary depending on the
opons selected for the device.
Controller c520
X61
X62
X237
X16
X50
X2x6, X2x7
X53
Cable fixing
PROFINET Device
Option
Reset
Without function
PE connection
Cable fixing
24 V supply
Commissioning, diagnostics
Ethernet
EtherCAT master
USB2
USB1
SD card
Status LEDs
3.3 SD card
An already inserted SD card is included in the scope of supply of the controller.
The combinaon of control technology soware and applicaon data on the SD card ensures
that the data match the prevailing applicaon in the present version. The SD card serves to
easily exchange data in a dierent device.
The SD card is used as memory for the following applicaon data:
•PLC boot project with parameter descripon
•Applicaon credit for the FAST applicaon soware
•Retain and logbook data
•User data (SD card/userData folder)
•Open source license descripon
Note:
•The controller only works with a plugged-in SD card!
•Removal of the SD card while the controller is running will lead to a system failure!
•The SD card is required for the system start since it contains the system les for the
starng process.
•If the SD card is removed, the controller must be restarted to enable a new access to the
card!
The operang system of the controller and the applicaon soware »FAST« are stored in the
internal ash memory of the controller.
For using a rmware update, include a memory reserve of 200 MB on the SD
card!
Product informaon
Idencaon of the products
12

3.4 Backplane bus
The I/O system 1000 can be directly connected to the integrated backplane bus. The individual
modules of the I/O system are parameterized in the »PLC Designer«.
Only EPM-Sxxx I/O compound modules from hardware version 1B onwards are
supported.
Detailed informaon on the I/O system 1000 can be found in the corresponding
documentaon: www.Lenze.com à Downloads
When using I/O terminals on the backplane bus, the EPM-S701 power supply
module is required as the rst module.
3.5 Licence informaon
Lenze Soware may contain soware elements that are licensed as free
soware or open source. The licensing terms and condions of the open source
soware components used in this product can be found in the "License"
directory on the SD card included in the product.
Product informaon
Backplane bus
13

4 Mechanical installaon
4.1 Mounng the controller
Mounng and dismounng of the controller
5
34
12
6
A
Mechanical installaon
Mounng the controller
14

5 Commissioning
This chapter contains informaon on how to commission and integrate the controller into an
automaon system.
Required accessories
•Engineering PC with »PLC Designer« installed.
•Standard network cable
5.1 Installaon of »PLC Designer«
For the installaon, download the »PLC Designer« from the download area on the Lenze
homepage to your PC and run the setup le.
www.Lenze.com à Downloads
5.2 Commissioning
Recommended sequence of the commissioning steps
1. 4Connect controller and Engineering PC ^ 16
2. 4Set IP address on the PC ^ 16
3. 4Start controller ^ 17
4. 4Create PLC program ^ 19
5. 4Create task ^ 20
6. 4Compile PLC program code ^ 20
7. 4Establish connecon between controller and »PLC Designer« ^ 20
8. 4Log in to the controller (load conguraon) ^ 21
9. 4Parameterize controller ^ 22
10. 4Device name ^ 25
11. 4Start PLC program ^ 24
Commissioning
Installaon of »PLC Designer«
15

5.3 Connect controller and Engineering PC
A communicaon link from the engineering PC to the controller is required to commission the
controller with the »PLC Designer«. This communicaon link must be wired.
NOTICE
Unstable LAN connecon due to the use of incorrect cable types.
The LAN connecon may be interrupted.
▶Exclusively use cables of the CAT5-S/FTP type or beer.
▶The unit is to be connected only to internal Ethernet networks without exing a facility and
being subjected to TNVs.
In the "as delivered" condion, the IP address in the controller is preset to
192.168.5.99 so it can be commissioned quickly.
If you would like to change the IP address, you will nd more informaon in chapter 4Staon
name and IP conguraon ^ 74.
How to establish a physical connecon between the controller and the engineering PC:
1. Plug the network cable into the engineering port X16 of the controller.
2. Use the network cable to connect the controller to the PC.
The controller is connected to the engineering PC.
A ping command can be issued from the console to test the availability of the controller using
the current IP address 192.168.5.99 or the newly congured address.
Addional informaon on conguring the network: 4Congure engineering port ^ 34
5.4 Set IP address on the PC
Recommended IP address for the engineering PC: 192.168.5.100
Standard IP address of the controller: 192.168.5.99
How to set the stac IP address of the Engineering PC:
Precondions
•Direct connecon between the engineering PC and the controller
1. Open the Network connecons diagnoscs window.
Control Panel\Network and Internet\Network Connections
2. Select the network interface which is connected to the controller.
3. Right-click on Properes.
4. Select Internet Protocol (TCP/IP).
5. Click on the Properes buon.
6. Select the Alternate Conguraon tab.
7. Select the User-dened opon.
a) Enter the IP address of the engineering PC that matches the IP range of the controller.
b) Enter the subnet mask of the engineering PC.
8. Click OK to close the dialog box.
Commissioning
Connect controller and Engineering PC
16

5.5 Start controller
Precondions
•SD card is inserted.
•Controller is supplied with voltage via the terminal X50.
•If I/O system 1000 modules are used, these must be installed on the backplane bus before
the start-up.
The controller requires approx. 30 seconds to start up.
The starng sequence is displayed in the LED blinking paern. When the device is ready for
operaon, the "RDY" LED lights up in blue.
If there is a boot project on the SD card, the corresponding PLC project is started. The status is
indicated by the "RUN" LED.
An error is indicated by the "ERR" LED. Details about the error can be found in the status
informaon in the device and in the logbook. 4LED status display ^ 93
LED status display
"RDY" LED (blue/yellow) Meaning
O Device is switched o.
Device is starng up.
Device is ready for operaon.
Voltage is underrun.
LED status display
"RUN" LED (yellow/green) Meaning
PLC project is being loaded.
PLC project is stopped.
PLC project is started.
Commissioning
Start controller
17

5.6 Access to SD card
The »PLC-Designer« provides access to the SD card.
How to use the »PLC-Designer« to access the SD card:
Precondions
•»PLC-Designer« is running.
•SD card is inserted.
1. Select the controller.
2. Select the Files tab in the project tree.
3. Click the update symbol.
The SD card directory is displayed.
You can also use an sp connecon to access the SD card.
You will nd informaon on establishing a connecon in the Lenze Knowledge
Base: www.Lenze.com.
The SD card's write protecon must not be acve for use in the controller.
If write protecon is acvated, the PLC applicaon will not start. Retain, boot
project and logbook informaon will not be saved.
Only use SD cards provided by Lenze. Only these SD cards have the
corresponding licensing.
Commissioning
Access to SD card
18

5.7 Create PLC program
How to create a PLC program in the target system:
Precondions
•»PLC Designer« has been started. 4Start controller ^ 17
•A new project has been created or a technology FAST applicaon template has been
opened.
1. Select the Add Device menu command.
2. Select the controller.
3. Add the backplane bus I/O modules.
4. Add the network module.
Commissioning
Create PLC program
19

5.8 Create task
How to create a task:
Precondions
•The PLC program has been created in the target system. 4Create PLC program ^ 19
1. Select the Add Object/Task command from the Task Conguraon context menu.
A task is created.
2. Enter a cycle me for the task created.
When using the EtherCAT master, the task cycle me of the main program part
must correspond to the set DC cycle me.
3. Select the Add Object command from the Applicaon context menu.
A program block is created in the applicaon.
4. Click the Add call buon.
A dialog opens.
5. Select the program call under Applicaon and click OK to conrm.
5.9 Compile PLC program code
The parameterizaon for the device is created automacally in the background
when the PLC program code is compiled.
How to compile the PLC program code:
Precondions
•A task has been created.
1. Conrm with the Build Compile menu command or with the <F11> funcon key.
2. If no errors have occurred during the compilaon process, save the »PLC Designer« project
in the project folder.
The parameter list is shown in the Controller tab. Detailed parameterizaon adjustments can
be made there. 4Parameterize controller ^ 22
If errors occurred during the compilaon process, they can be located and
corrected on the basis of the »PLC Designer« error messages. Subsequently, re-
compile the program code.
5.10 Establish connecon between controller and »PLC Designer«
How to connect the »PLC Designer« with the controller:
Precondions
•The PLC program code has been compiled.
1. Go to the Communicaon sengs tab of the target system (device) and click the Add
gateway buon.
2. Enter the IP address of the controller in the Gateway dialog box.
3. Click OK to conrm the entry.
4. Click the Scan network buon.
5. Select the controller for the IP address entered and conrm by clicking the Set acve path
buon.
The controller is now connected with the »PLC Designer« and appears in the project tree
under its assigned name. If a device name has not yet been assigned in the project (standard
name = "Device"), the device will be displayed with its device type and MAC address in the
default seng.
Example: c550-000A86123456.
Commissioning
Create task
20