Moeller SmartWire User guide

SmartWire Startup Guide V1.02
SmartWire Startup Guide V1.02
© by Moeller GmbH 1 / 42

SmartWire Startup Guide V1.02
The document can be found under the following path:
ftp://ftp.moeller.net/SMARTWIRE/ENGLISH/01_PRODUCT/08_STARTUP_GUIDE
{ DOWNLOAD }
All rights, including those of translation, reserved. No part of this manual may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means,
electronic, mechanical, photocopying, micro-filming, recording or otherwise, without
the prior written permission of Moeller GmbH, Bonn.
Changes:
V1.0 ÆV1.01 Moeller logo updated
V1.01 ÆV1.02 Screenshots updated
© by Moeller GmbH 2 / 42

SmartWire Startup Guide V1.02
Contents
1Introduction...................................................................................................... 4
2System components for motor starters with SmartWire.............................. 5
3Connections on the motor starter .................................................................. 7
4Assembling a motor starter row..................................................................... 8
5Electrically commissioning SmartWire........................................................ 10
6SmartWire integration for XC100/200 via Profibus DP................................ 12
6.1 PLC connection.............................................................................................................12
6.2 Installing the GSD file ...................................................................................................13
6.3 Creating a program in easySoft CoDeSys....................................................................14
6.4 Setting for Profibus node monitoring.............................................................................21
6.5 Diagnostics ...................................................................................................................22
6.5.1 XC100/200 system diagnostics................................................................................................... 22
6.5.2 Profibus DP diagnostics.............................................................................................................. 24
6.6 Example program for XC200 (SWIRE-XC200-ProfibusDP.pro)....................................27
7SmartWire integration for XC100/200 via CANopen.................................... 28
7.1 PLC connection.............................................................................................................28
7.2 Installing the EDS file....................................................................................................29
7.3 Creating a program in easySoft CoDeSys....................................................................29
7.4 Settings for CANopen node monitoring with Node guarding.........................................33
7.5 Settings for the CANopen Heartbeat node monitoring..................................................34
7.6 CANopen slave monitoring ...........................................................................................35
7.7 Example program for XC200 (SWIRE-XC200-CANopen.pro)......................................39
8SmartWire integration for easy800 via easyNET......................................... 40
9SmartWire integration for ECP4 via CANopen ............................................ 40
10 SmartWire integration for S7-300 via Profibus DP...................................... 40
© by Moeller GmbH 3 / 42

SmartWire Startup Guide V1.02
1 Introduction
SmartWire enables switching devices to be connected to a PLC without the need for
any complex control circuit wiring. The control wiring between the PLC and the
switchgear is replaced by the plug-in SmartWire module and pre-assembled
connection cables. The wiring requirement is drastically reduced and thus makes
wiring errors a thing of the past. This saves time and money during mounting,
commissioning and troubleshooting during operation.
SmartWire is an addition to the well-established range of Moeller switchgear and is
designed to be an accessory for standard devices. The flexibility of the switchgear is
fully retained since all known system accessories can still be used. The use of
standard devices reduces the stock-keeping costs required and ensures the
worldwide availability of replacement parts.
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SmartWire Startup Guide V1.02
2 System components for motor starters with SmartWire
(4)
(6)
(1)
(5) (2)
(3)
The following pages describe the setup, configuration and function of the SmartWire
system using eight Moeller motor starters with the "SWIRE-DIL" SmartWire module
for DILM contactors.
The motor starters presented here consist of 5 components:
1) PKZM motor-protective circuit-breaker
2) Connection element
3) DILM contactor
4) Tool-less plug connector
5) SmartWire module for DILM "SWIRE-DIL"
6) SmartWire connection cable "SWIRE-CAB-xxx"
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SmartWire Startup Guide V1.02
A motor starter is assembled simply from these 5 components.
Before fitting the SWIRE-DIL to the corresponding contactor, it must be ensured that
the position of the terminal pin is set correctly.
DILM contactor size 1 DILM contactor size 2
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SmartWire Startup Guide V1.02
3 Connections on the motor starter
L1 L2 L3
M
Wiring for motor
feeder
(AC load circuit)
Incomer wiring
(AC load circuit)
X1/X2 optional wiring
NHI (auxiliary contact
for PKZM)
X3/X4 for opening
the contactor control circuit
(Jumpered as standard)
The SWIRE-DIL has 4 screw terminals, X1/X2 and X3/X4.
X1/X2 is provided with a digital input for isolated contacts. This input is designed for
connecting the NHI auxiliary contact of the PKZ and thus indicates the status of the
PKZ (off/tripped and on) to the SWIRE-DIL.
A jumper (fitted as standard) at X3/X4 closes the control circuit for the contactor.
Opening the connection at X3/X4 makes it possible to interrupt the circuit for the
contactor (independently of the SWIRE-DIL control logic). X3/X4 enables, for
example, the electrical interlock of the contactor for a reversing starter combination.
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SmartWire Startup Guide V1.02
4 Assembling a motor starter row
The assembly of the system couldn't be easier. The motor starters are firstly fitted in
succession onto the mounting rail. The NHI may have been installed on the PKZ
beforehand and the connection cables connected to the terminal X1/X2.
All SWIRE-DILs are then interconnected using the SmartWire connection cables. The
SWIRE-CAB-008 is recommended for connecting two starters with (DILM7…11
contactors). If adjacent contactors are not identical, e.g. DILM9 next to DILM15 or
vice versa, the next larger connection cable SWIRE-CAB-011 is recommended.
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SmartWire Startup Guide V1.02
© by Moeller GmbH 9 / 42
The next step involves the installation of the fieldbus gateway. The following
interfaces are possible at present:
1) SWIRE-GW-DP Æfor connecting to Profibus DP V0
2) easy223-SWIRE ÆCANopen mode: for connecting to a CANopen master
3) easy223-SWIRE ÆeasyNET mode: for connecting to an easyNET for easy800
Ideally, the fieldbus gateway is positioned approx. 10 mm away from the first starter.
SWIRE-CAB-015 is recommended as the SmartWire cable.
The gateway requires two operating voltages:
a) UInterface : used for supplying the gateway and the SmartWire modules.
b) UAux : supply voltage here for the contactors on the motor starter
ATTENTION!
The power supply must be provided with appropriate fuse protection.
a) UInterface : 1A fuse
b) UAux : 3A fuse
Further information on this is provided in the technical descriptions (AWBs) of the
SmartWire components.
24VDC power
supply
for SWIRE devices
24VDC incomer
for DILM contactors
Distance from gateway to
the first starter, ideally
approx. 10mm

SmartWire Startup Guide V1.02
5 Electrically commissioning SmartWire
The SmartWire system which is connected to the higher-level PLC via the fieldbus
gateway in place can be configured independently of the controlling PLC and
commissioned.
After the power supply is switched on, the SmartWire gateway always checks the
connected SmartWire modules and compares this with the internally stored
configuration. The SmartWire gateway is factory set without a reference
configuration. In other words, it does not expect to find any modules.
In this example with 8 motor starters and thus also SmartWire modules, the
SmartWire gateway will detect the deviation when the first module is checked. This is
indicated by the regular flashing of the SmartWire LED on the gateway and on the
first SWIRE-DIL. The LEDs of SWIRE-DILs 2-7 flash in pulses.
This means that they are in operation but have not yet been accessed by the
gateway, since the first module does not match the reference configuration in the
SmartWire gateway.
The currently connected configuration can be transferred by pressing the
configuration button on the gateway. This must be held down > 1 second. If this time
is exceeded, the Ready LED will change from slow to fast flashing and will thus
indicate that the configuration process has been initiated. The configuration button
can then be released.
The gateway then carries out an automatic configuration so that all stations are
addressed in turn (in this case 1-8).
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SmartWire Startup Guide V1.02
Once this configuration of the gateway has been completed successfully, this is
indicated by the permanently lit SWIRE-LED on the gateway and all permanently lit
Ready LEDs on the SmartWire modules (apart from the SWIRE-DILs). This means
that the actual configuration has been accepted by the gateway and stored internally.
The complete SmartWire system is now fully operational.
Note: during the configuration, the SmartWire gateway addresses the connected
stations in turn. With a maximum configuration the modules are numbered from 1-16.
The only other steps required apply to the fieldbus system and its configuration, as
well as the programming in the higher-level PLC.
The following chapters describe the integration of the SmartWire system consisting of
SmartWire gateway and SmartWire modules.
The previously described configuration of 8 motor starters with the 8 SWIRE-DIL
modules is used as an example.
© by Moeller GmbH 11 / 42

SmartWire Startup Guide V1.02
6 SmartWire integration for XC100/200 via Profibus DP
This section assumes the following example PLC configuration:
•Moeller XC-CPU201-256K-8DI-6DO
•Moeller XIOC-NET-DP-M (Profibus master module for Moeller XC100/200)
easySoft CoDeSys V2.3.5.8 (Build Dec 7 2005) is used for programming. The current
service pack ECP_Update01_07.exe should also be installed. The service pack can
be downloaded from the Moeller ftp server at the following address:
ftp://ftp.moeller.net/AUTOMATION/DOWNLOAD/SOFTWARE_UPDATES/EASYSOF
T_CODESYS/V2.3.5/
6.1 PLC connection
The Profibus DP master module is connected via a standard Profibus fieldbus cable
to the SWIRE-GW-DP SmartWire gateway. It must be ensured that the bus ends of
the Profibus DP connection cable are correctly terminated.
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SmartWire Startup Guide V1.02
6.2 Installing the GSD file
The configuration of the master and slave devices in easySoft CoDeSys is based on
the GSD files. These device data files are supplied by the manufacturer and contain
a standard description of the characteristic properties of a PROFIBUS DP device.
Ensure that the required GSD files are already located in the specified directory for
the configuration files before CoDeSys is started.
The following GSD files are required for the SmartWire Profibus DP gateway.
Moe4D12_Intel V1_5.zip
PROFIBUS-DP device data file (GSD) for SWIRE-GW-DP DPV0 slave
GSD files for PLCs operating with the Intel data format.
(e.g. Moeller PS4, XC100, XC200...)
They can be downloaded from the Moeller ftp server at the following path:
ftp://ftp.moeller.net/AUTOMATION/DOWNLOAD/
CONFIGURATIONFILES_CFG_GSD_EDS/SEVERAL_PARTS/
PROFIBUS/SMARTWIRE/
{ DOWNLOAD }
Copy all the files in the zip folder to the following easySoft CoDeSys folder:
C:\Programs\Moeller Software\easy Soft CoDeSys V2.3.5\easy Soft
CoDeSys\Library\PLCConf
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SmartWire Startup Guide V1.02
6.3 Creating a program in easySoft CoDeSys
First start the easySoft CoDeSys software and create a new project (in this case for
XC200).
Then define the language for the MAIN program (in this case ST)
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SmartWire Startup Guide V1.02
Then select the Resources tab and select PLC configuration
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SmartWire Startup Guide V1.02
At the point with the first EMPTY SLOT add the Profibus DP master module (XIOC-
NET-DP-M):
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SmartWire Startup Guide V1.02
The Profibus DP slave (in this case SWIRE-GW-DP) can then be added to the PLC
configuration.
The Profibus DP slave address must be added in the DP Parameters tab for the
XIOC-NET-DP-M module. In this case 3 is selected.
Version of the
GSD file
Node address of
the Profibus slave
SWIRE-GW-DP
The currently valid version of the GSD file for the SWIRE-GW-DP is V1.5
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SmartWire Startup Guide V1.02
The setting of the Profibus node address is made via the DIP switches on the
SWIRE-GW-DP:
The reference configuration on the SmartWire line is defined in the Inputs/Outputs
tab. This configuration is awaited by the Profibus DP master during the startup. If the
reference configuration of the SmartWire line set here does not match the actual
configuration, the SWIRE-GW-DP operation will not start up properly.
In this example a SmartWire line was set up with 8 motor starters and therefore also
8 SWIRE-DIL modules.
Setting of the
Profibus address via
DIP switches
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SmartWire Startup Guide V1.02
The reference configuration must therefore be set as follows:
Each SmartWire module has assigned to it a specific address area for status and
control data. A total of 2 bytes is reserved for the SWIRE-DIL module.
In this example one byte is reserved for the control data (%QB2) of the first SWIRE-
DIL and one byte for the status data (%IB6). The other bytes are assigned in
ascending order accordingly for the other SWIRE-DIL modules.
The absolute addresses can be used directly in the PLC program.
The following assignment is used for the SWIRE-DIL:
Control data for SWIRE-DIL (%QX…)
bit Function
0 Contactor (on/off)
1 n.n.
2 n.n.
3 n.n.
4 -----
5 -----
6 -----
7 -----
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SmartWire Startup Guide V1.02
Status data for SWIRE-DIL (%IX…)
bit Function
0 Contactor switch position (on/off)
1 PKZ switch status (tripped/on)
2 n.n.
3 n.n.
4 n.n.
5 n.n.
6 n.n.
7 Slave status (0=ok, 1=internal error) *
* = Note: This bit must not be confused with the Profibus DP diagnostic data block. It
is cyclically transferred with the process data and indicates an internal device error.
In the event of a fault on the SmartWire module, this bit is not set in certain cases.
The basic function of the module on the SmartWire must therefore be monitored via
the Profibus diagnostics. This is described on the following pages.
Another SmartWire module is currently available. This is a digital I/O module with the
designation SWIRE-4DI-2DO-R. It has 4 digital inputs for potentially isolated contacts
and 2 digital relay outputs.
This module has the following control and status byte assignment:
Control data for SWIRE-4DI-2DO-R (%QX…)
bit Function
0 Digital output Q1
1 Digital output Q2
2 n.n.
3 n.n.
4 -----
5 -----
6 -----
7 -----
Status data for SWIRE-4DI-2DO-R (%IX…)
bit Function
0 Digital input I1 (on/off)
1 Digital input I2 (on/off)
2 Digital input I3 (on/off)
3 Digital input I4 (on/off)
4 n.n.
5 n.n.
6 n.n.
7 Slave status (0=ok, 1=internal error)
© by Moeller GmbH 20 / 42