Lust CDA3000-PLC User guide

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ACHTUNG
Kondensatorent-
ladezeit >3 Min.
Betriebsanleitung
beachten!
WARNING
capacitor disscharge
time >3 minutes.
Pay attention to the
operation manual!
ATTENTION
temps de decharge
du condensteur
>3 min. observer le
mode dèmploi!
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D- 35633 Lahnau
Type: CDA32.004,C1.0
In: 230 V + 15/-20%
50/60 Hz 1,7 kVA
3x0-230 V 4 A
0,75 kW 0-400 Hz
Out:
SN.: 99120442
VT505W
shift
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12
CDA3000-PLC
Sub-automation unit
with c-line DRIVES
EN
EN
FR
IT
ES
System manual

System manual CDA3000-PLC
Id.-No.: 0840.12B.1
Stand: 05/.2003
Valid from CDA3000-software version V700.10
We reserve the right to make technical changes.

Sub-automatisation unit with c-line DRIVES
How to use this guide
1 Introduction
2 System survey
3 Sub-automatisation units
4 Commissioning of PLC-system
5 Order data of system components
1
2
3
4
5
Directory

Sub-atuomatisation unit with c-line DRIVES
Pictographs
➢ Attention! Faulty operation can cause damage or mal-
function of the drive system.
➢ Here you will find further comparable applications.
➢ The symbol stands for hurdles and barriers, which
have to be cleared during realization of the concept.
➢ Note: What you have to know, information in short
form.

Sub-automatisation unit with c-line DRIVES
1 Introduction
1.1 Thinking in machine sub-automation units ...........1-2
1.2 Typical machine sub-automation units .................1-4
2 System survey
2.1 Software package CDA3000, PLC ...........................2-2
2.1.1 PLC-Editor ...........................................................2-2
2.1.2 PLC-Firmware ....................................................2-11
2.1.3 DRIVEMANAGER .....................................................2-20
2.2 Operator panels for c-line DRIVES .........................2-21
2.3 SMARTCARD / KEYPAD ..............................................2-31
2.4 Training .................................................................2-32
2.5 Service-know-how for your projects ...................2-34
3 Sub-automation units
3.1 Time-controlled luggage belt-drive .......................3-2
3.2 Drill feed unit ...........................................................3-4
3.3 Shredder with overload detection ..........................3-7
3.4 Unwinder for wire .................................................3-11
3.5 Diameter depending speed control ......................3-13
3.6 Simple positioning drive with PLC_3 ...................3-15
4 Commissioning of PLC-system
4.1 First commissioningCDA3000, PLC ........................4-1
4.2 First commissioning of
operator panels .......................................................4-4
4.2.1 Configuration of RS232-interface .........................4-4
4.2.2 Configuration of CANopen-network .......................4-6
5 Order data of system components

Sub-automatisation unit with c-line DRIVES 1-1
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1 Introduction
Due to the increased pressure to reduce costs a new slogan is born in the
automation industry. Sub-automation unit - a catchword, which will be
used more and more. What is the difference between this solution and
others, what are the advantages?
This manual clears these and other questions. It is made for all users of
inverters and servocontrollers as well as for people technically interested,
looking for new solutions. Salespeople, specialists and executives will get
an impression of new economic solutions.
The manual includes the following five ranges:
➢ Chapter 1: General introduction
➢ Chapter 2: System survey
➢ Chapter 3: Sub-automation units
➢ Chapter 4: Commissioning of PLC-systems
➢ Chapter 4: Order data of system components

1-2
Sub-automatisation unit with c-line DRIVES
1 Introduction
1.1 Thinking in
machine sub-
automation units
Thinking in machine sub-automation units requires in the drive units a
free-programmable core inside, named PLC. Because the contribution to
the solution of sub-automation units depends more and more on the flexi-
bility of the PLC-user plattform within the drive system. Finally, only the
software offers the „intelliegence“ and so the method to get over the
motion solution.
Seeing driving problems from a process oriented standpoint, always the
complete system has to be taken into consideration. Large complex
machines and instruments have to be disassembled in small clear sub-
automation units. In machine sub-automation units, doing a job automati-
cally and inevitably following to a set procedure. Normally such sub-auto-
mation units reflect the mechanical and electrical construction unit.
Please note at realization of new solutions that the procedure of sub-
automation units is enclosed. That means that a changing of conditions
cannot be made directly via an other sub-automation unit, it can only
adjusted via a „clear defined interface“.
picture 1.1 PLC-user plattform
BASIC FIRMWARE
HARDWARE - PLATFORM
T1 T2 T3 T ... n
M1
F
P2
10
b1
T
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S3
SM1
S1 RNOK S2
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10V
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b1
ω
ω
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M1
PLC - USER PLATFORM
machine sub-automation unit
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ANTRIEBSTECHNIK
SN.:
000.000.00000000
Typ:
Netz:
Ausg.:
D-35633Lahnau
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b1

Sub-automatisation unit with c-line DRIVES 1-3
1 Introduction
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Special at this solution is that the sub-automation unit can be used in
other machine types, requiring the same sub-automation unit, without
changing the program.
Coupling of sub-automation units to one „function unit“ allows the co-ordi-
nation of complex procedures. In the function unit one of the sub-automa-
tion units manages the coordination of the whole function unit as well.
However, the function of other sub-automation units will be required via
the already mentioned „clear defined interface“.
picture 1.2 sub-automation unit - drill unit
picture 1.3 function unit - drilling appliance
M2
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S1
S3
M1
b1
W1 M3
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M2
b1
S4
S3

1-4
Sub-automatisation unit with c-line DRIVES
1 Introduction
The complete automatic process is clearly structured resp. is divided in
closed machine sub-automation units. Sub-automation units, allowing
unitizing of machine types and having a high reusability. Serial commis-
sioning can be made without special knowledge or PC, simply via SMART-
CARD - plug-in, load and run.
1.2 Typical machine
sub-automation
units
The already cleared machine sub-automation units can typically divided
in three groups:
I/O-oriented sub-automation unit
Motion solutions, processes are mainly defined by means of I/O-signals.
Typical applications are: advance unit for drilling or sinking, belt and car-
riage drives, drives for doors and gates as well as pump stations with float
switches.
Time-controlled sub-automation unit
Motion solutions, processes are mainly time-controlled. Typical applicati-
ons are: melting and mixing plants for paints and other materials, different
centrifuges as well as mills and shredder.
Controlled sub-automation unit
Motion solutions, for controlling process variables like torque, traction,
pressure, temperature or position. Typical applications are wobbler and
dancer control for winders, block-protection for shredder, simple posi-
tioning jobs for drives, rotating, as well as drives for doors and gates and
the classic pressure, temperature and flow control.

Sub-automatisation unit with c-line DRIVES 2-1
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2Systemsurvey
The system consists of the following components:
• Drive CDA3000 with accessories and option modules
• Software package CDA3000-PLC
• Different operator panels with accessories
picture 2.1CDA3000-PLC System survey
K EY P AD
KP200-XL
Communication module
- PROFIBUS-DP via CM-DPV1
- CANopen via CM-CAN1
S
MART C ARD
SC-XL
PLC-Program-Editor
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21 22 23 24 25 26 27 28 29 30
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Parameter
start
enter stop
return
VAL
Hz
Shift F2 F3 F4F1
Esc
Help
Info
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VT50
SN.: 002301271
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Help
PgUp
PgDn
Esc
Clr
Integrated
PLC
control functions
Operator-Panels
User modules
- I/O-Module (8E/4A) UM-8I4O
Programming system for
Operator-Panels

2-2
Sub-automatisation unit with c-line DRIVES
2 System survey
2.1 Software pak-
kage CDA3000,
PLC
The software package CDA3000-PLC consists of three parts:
• PLC-program editor on CD-ROM. The PLC-editor is additionally to
the DRIVEMANAGER.
On CD-ROM you will find this system manual as well as PLC and
device standard software. Furthermore it incl. additional product
documentation (user manual CDA3000, communication modules)
• PLC-device firmware V700.xx for CDA3000
•D
RIVEMANAGER V3.20 (or higher version) on CD-ROM.
2.1.1 PLC-Editor The PLC-program editor will be delivered on a separate CD-ROM as
installation version. In German and English available.
The PLC-editor is part of the DRIVEMANAGER and so it can only be used
with DRIVEMANAGER. This presumes that a DRIVEMANAGER with version
V3.20 and higher is installed on the PC.
The PLC-editor is only necessary for the engineering resp. first commis-
sioning, a serial commissioning of the drive controller will be made via
DRIVEMANAGER-data set or SMARTCARD.
picture 2.2 PLC-editor

Sub-automatisation unit with c-line DRIVES 2-3
2 System survey
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The PLC-program editor offers the following functions:
• Program production
− Editor for program production
− Generating a text declaration file <project name>.txt for varia-
bles to show application specific texts in the DRIVEMANAGER.
− Syntax check of command code
− Renumbering of line numbers
• Program-Handling
− Load/Save/Print/New production of programs
− Load/Save a program from/in the connected drive
Load/Save a program from/in the DRIVEMANAGER data set
• Online-Help for PLC-Editor and for command syntax with examples
All PLC-functions are selectable via function switches (buttons)
New program Open program as file Save program as file *.plc Cut text Copy text Paste text Undo Search/Replace Print program Online help Program syntax check Renumbering of line numbers Load program from data set Save program in data set Load program from device Save program in device

2-4
Sub-automatisation unit with c-line DRIVES
2 System survey
PLC-Program process A program is divided in two parts:
1. Text declaration for used variables, flags, counter and timer
2. PLC-program
The Text declaration is for marking of used variables, counters and
timers in the PLC-program with the application specific function. A text file
will be generated out of the text declaration, evaluated in the DRIVEMANA-
GER, shows the parameters with application specific texts.
The text declaration starts with the designator, obtains the the project
name of the text declaration file (for details see „PLC-program data“).
%TEXT (project name) ; Start text declaration
An assignation of the parameter texts follows:
DEF M000 = setpoint_OK
DEF H000 = reference_pos_1
DEF H001 = reference_pos_2
DEF H002 = actual_pos
DEF H003 = Zero correction
End of the text declaration always with:
END
The text declaration is optional. Non-declared PLC-parameters will not be
saved in the text file resp. displayed with its number in the DRIVEMANA-
GER.
The PLC-program attach to the text declaration. It contains a program
head, the true program part and the program end.
The program head consists of a line, includes the program number (here
only %P00 possible):
%P00
The lines of the program part are called command lines. The number of
the sets, which can be saved in the CDA3000, is limited to 254 (N001 ...
N254). Each command line consists of line number, command and ope-
rand. Via semicolon a command can be inserted.
picture 2.3 Indication of PLC-parameters with application specific texts

Sub-automatisation unit with c-line DRIVES 2-5
2 System survey
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N030 SET M000 = 0; Setpoint not defined
Program ends always with line (without line number):
END
For program examples see chapter 3 or already installed DRIVEMANAGER-
directory„..\userdata\PLC“.
Program check and processing For quickstart resp. new producing of a PLC-program call for syntax
check with blank text field. Now the PLC-editor offers the producing of a
program body.
The syntax check checks if there are any errors in the command codes
of the actual program. It will be executed automatically at saving of the
program in the drive or manually via the appropriate button. The result of
the check will be indicated in the status rail. In case of any error message,
it is possible via double-click on the appropriate message to jump directly
to the faulty program line.
The renumbering of line number ease inserting a program set. At renum-
bering the first line gets the number N010, all other will be incremented by
steps of 10 (N020, N030, ...). If it is not possible to show a program in the
stated line ranges (001-254), the steps will be reduced automatically.
PLC-Program files The program content will be stored in two files:
1. Program file *.plc
This file consists the PLC- program as well as text declaration and so
the complete program information. In case of transfering the PLC-
program it is sufficient to copy the file.
2. Text declaration file <Project name>.txt
The file will be used from the DRIVEMANAGER to indicate the applica-
tion specific parameter names.
It will automatically generated upon succesful program download in
the drive controller or in a data set of the text declaration of the pro-
gram file. The file <Project name>.txt will be copied in the DRIVEMA-
NAGER file „LUST DriveManager\firmdata\<Project name>.txt“. This
file is only available on the PC, generated this program resp. loaded
the source code in the drive controller. However it can be copied to
other PCs.
To reproduce all program information resp. data each program has to be
saved as file *.plc.
The comment lines of the process program and the text declaration are
not saved in the drive or in device data sets, that means a read-back is
not possible.

2-6
Sub-automatisation unit with c-line DRIVES
2 System survey
There are 3 ways to open an available PLC-program:
• Double-click on file *.plc. Then DRIVEMANAGER opens and it starts
the PLC-editor and opens the program.
• Opening via DRIVEMANAGER menu „File/Open/PLC-process program
...“
• Opening via already started PLC-editor
picture 2.4 Open PLC-program via DRIVEMANAGER

Sub-automatisation unit with c-line DRIVES 2-7
2 System survey
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PLC-command syntax .
Comm
and Operand Note
Jump command
JMP Ny/END Absolute jump
(Ippi = 0/1) Ny/END Condition of input
(Oppi = 0/1) Ny/END Condition of output
(Mxxx = 0/1, = != Myyy) Ny/END Condition of flag
(Mxxx & | ^ Ippi) Ny/END Logical link flag-input
(Mxxx & | ^ Ippi) Ny/END Logical link flag-output
(Cxx = != 0 .. 255) Ny/END Counter status
(Zxx = != 0) Ny/END Timer status
(Hxxx = != 0, = != < <= > >= Hyyy) Ny/END Size of integer variables
(Fxxx = != 0.0, = !=
< <= > >= Fyyy) Ny/END Size of floating point variables
Set commands
SET Oppi = 0/1, Mxxx Set output diretly or with flag
Mxxx = 0/1, Ippi, Oppi, Myyy, M[Cxx] Set flag
Mxxx = Hyyy Set flag (LSB of Hyyy)
M[Cxx] = Mxxx Set flag (indicated)
Mxxx & | ^ Myyy Logical link of flag
Cxx = d, Cyy, Hyyy Set counter
Cxx + - d, Hyyy Calculate counter
Zxx = d, Hyyy Set timer
Hxxx = z, Hyyy, H[Cyy], Fyyy, Cyy, Zyy,
PARA[n, i], PARA[n],
PARA[Hxxx,Hyyy], PARA[Hxxx]
Set variable
At processes with floating point
variables the value range will be
limited automatically. No error mes-
sage follows.
H[Cxx] = Hyyy Set variable (indicated)
Hxxx & | ^ Hyyy Logical link of variables
Hxxx << >> b, Hyyy Move variable
Hxxx + - * : % z, Hyyy Calculate variable
Hxxx = ABS Hyyy Built variable amount
Fxxx = f, Hyyy, F[Cyy], Fyyy, PARA[n, i],
PARA[n], PARA[Hxxx,Hyyy],
PARA[Hxxx]
Set floating point variable. At proces-
ses with floating point variables the
value range will be limited automati-
cally. No error message follows.
F[Cxx] = Fyyy Set floating point variable (indicated)
Fxxx + - * : f, Fyyy Calculate floating point variable
Fxxx = ROUND Fyyy Round floating point variable
Fxxx = ABS Fyyy Built floating point amount

2-8
Sub-automatisation unit with c-line DRIVES
2 System survey
SET PARA[n, i], PARA[n],
PARA[Hxxx,Hyyy], PARA[Hxxx] = Hyyy, Fyyy Set parameter
BRKPT = 0 Deactivate brakepoint logic
BRKPT = 1 Activate brakepoint logic
Hxxx = OUTPUT, INPUT Read variables with image of output
resp. input
Hxxx, Fxxx = ACTFRQ Read actual frequency [Hz]
Hxxx, Fxxx = ACTSPEED Read actual speed [rpm]
Hxxx, Fxxx = ACTPOS Read actual position [Incr]
Hxxx, Fxxx = REFPOS Read reference position [Incr]
Hxxx, Fxxx = ACTTORQUE Read actual torque [Nm]
Hxxx, Fxxx = ACTCURRENT Read actual current (effective) [A]
Hxxx = OSA0 Read analog output value
0 - 1023 = 0V - 10V
Hxxx = ISA0 Read analog input ISA0
-512 - 511 = -10V - +10V
Hxxx = ISA1 Read analog input ISA1
0 - 1023 = 0V - +10V
OUTPUT = Hyyy
Set output image
Only outputs with set function selec-
tor will be set FOxxx=PLC.
OSA0 = Hyyy
Set analog output
0 - 1023 = 0V - 10V
Condition: function selector
200-FOSA0 = PLC
REFFRQ = Hyyy, Fyyy
Write frequency reference to FOPT1
Reference is only active if reference
selector is set to
280-RSSL1=FOPT1 or
281-RSSL2=FOPT1.
INPOSWND = Hxxx Set reference reached window [incr]
(Default 100 incr.)
INPOSTIME = Hxxx Set reference reached time [ms]
(Default 20 ms)
Mxxx = STA_ERR Read error status
(1 -> error)
Mxxx = STA_WRN Read warning-status
(1 -> warning)
Mxxx = STA_ERR_WRN Read error/warning status
(1 -> error/warning)
Mxxx = STA_ROT_R Motor turns right (1)
Mxxx = STA_ROT_L Motor turns left (1)
Mxxx = STA_ROT_0 Motor standstill (1)
Comm
and Operand Note

Sub-automatisation unit with c-line DRIVES 2-9
2 System survey
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SET Mxxx = STA_ACTIV Motor/Control active (1)
Mxxx = STA_LIMIT Limitation (1)
Mxxx = STA_REF Reference reached (1)
Mxxx = STA_BRAKE Condition brake
(1 -> Brake active)
Mxxx = STA_OFF Condition de-energized (1)
Mxxx = STA_C_RDY Condition control ready (1)
Mxxx = STA_WUV Warning undervoltage (1)
Mxxx = STA_WOV Warning overvoltage (1)
Mxxx = STA_ WIIT Warning I2*t (1)
Mxxx = STA_WOTM Warning overtemperature motor (1)
Mxxx = STA_WOTI Warning heat sink temperature (1)
Mxxx = STA_WOTD Warning interior temperature (1)
Mxxx = STA_WIS Warning apparent current - limit (1)
Mxxx = STA_WFOUT Warning output frequency - limit (1)
Mxxx = STA_WFDIG Warning reference of master faulty
(1)
Mxxx = STA_ WIT Warning I*t (1)
Mxxx = STA_ WTQ Warning torque (only FOR and SFC)
(1)
ENCTRL = 0/1; Myyy
Stop/start control (Mxxx = 0/1)
Execution of function only if control
location CLSEL=PLC is set.
INV = 0/1; Myyy Invert reference
PCTRL = 0/1, Myyy Activate position controller
BRAKE = 0/1, Myyy Brake motor to 0 Hz
(1, Mxxx = 1)
ERR = 0/1, Myyy Release error switch-off
(1, Mxxx = 1)
Sub program call
CALL Ny Sub program call to line Ny
Max. nesting depth: 255
RET Reset to line of sub program call
Wait commands
WAIT d, Hxxx Waiting time in ms
(0 ... 4.294.967.295 ms)
WAIT PAR Wait until parameter is written.
Go commands (only for positioning control)
GO W A Hxxx
Go absolutely by value Hxxx and
wait for program processing until
target position is reached.
Comm
and Operand Note

2-10
Sub-automatisation unit with c-line DRIVES
2 System survey
Syntax of command index:
GO W R Hxxx
Go relative by value Hxxx and wait
for program processing until target
position is reached.
A Hxxx Go absolutely by value of Hxxx (pro-
gram processing continuous)
A Hxxx Go relatively by value of Hxxx (pro-
gram processing continuous)
0Referencing to 0 (reference position
=actual positon=0)
0+Hxxx Referencing to Hxxx (reference posi-
tion=actual position=0)
Further commands
NOP Instruction without function
INV Oppi, Mxxx, Hxxx Inverting
END
Finish program, all following lines
will be ignored. Do not enter a line
number.
BRKPT
SET BRKPT=1:
Sets a breakpoint in the program line
SET BRKPT=0:
no function
Comm
and Operand Note
Cxx, Cyy Counter index 00-10
Hxxx, Hyyy Integer-Variable index 000-
127
Fxxx, Fyyy Floating-Point-Variable indes
000-127
Zxx, Zyy Timer index 00-10
Ny line number 001-254
PARA[n, i] Parameter number n 000-999
Parameter index i 000-255
Mxxx, Myyy Flag index 000-255
Ippi, Oppi
Inputs
ppi = A00, A01
S00-S03, E00-E07
Oppi Outputs
ppi = S00-S02, E00-E03
b Value 1-32
dStatus of a counter
0 ... 255 (8 bit)
dStatus of a timer
0 ... 4.294.967.295 (32 bit)
fFloating point value
(32 bit)
zInteger value
±2147483648 (32 bit)