Murdoch University Engineering Thesis. Appendix VII. MOVITRAC B & DFP21B Configuration instructions

Transcription

1 Appendix VII MOVITRAC B & DFP21B Configuration instructions Author: Hao Xu Page: p335 - p403 Last modified: 10/11/2013 This is part of the Engineering Thesis WinCC SCADA System via Profibus & OPC by Hao Xu. 335 P a g e

2 Preface This configuration instruction provides a comprehensive description about the functions and operations of MOVITRAC B and DFP21B. The contents are summarized as follows: MOVITRAC B hardware modules description MOVITRAC B operation instruction MOVITRAC B diagnostic MOVITRAC B parameter list DFP21B operation description DFP21B slave module description DFP21B telegram structure DFP21B process data structure DFP21B communication diagnostic DFP21B slave module data exchange sample code DFP21B parameter list MotionStudio configuration TIA Portal communication configuration Prerequisite Background knowledge of variable speed drive operations Background knowledge of PLC operations Background knowledge of ladder logic diagram Background knowledge of basic electric circuit Background knowledge of Profibus communication Completion of Appendix V S7-300 PLC & RS485 Repeater configuration instructions Resources MOVITRAC B with FBG11B keypad module and FSC11B communication modules DFP21B gateway within UOH11B housing Appropriate single phase motor MOVITOOLS MotionStudio configuration software (Optional) USB11A RS485 to USB adaptor for MotionStudio communication (Optional) UWS21B RS485 to RS232 adaptor for MotionStudio communication (Optional) RS485 cable with RJ10 connector (Optional) S7-300 PLC with DP interface CP5611 Profibus interface PCI card TIA Portal configuration software Profibus cable Profibus DP connector MPI adaptor (Optional) 336 P a g e

3 MOVITRAC B (Refer to MOVITRAC B section in the thesis report for an overview of the functions and some background information) MOVITRAC B needs to be powered by 240V AC to operate and it only supports single phase motor. Table 79 is the description of the function of the terminals. Terminal Designation Function Data X10:1 REF1 +10V, I max = 3mA X10:2 AI11 (+) Analog input 0 10V X10:3 AI12 (-) (Differential input) 0 20mA/4 20mA X10:4 GND X12:1 DI00 X12:2 DI01 X12:3 DI02 X12:4 DI03 X12:5 DI04 X12:6 DI05TF Digital inputs X12:7 VOTF Supply voltage for TF X12:8 24VIO X12:9 GND X13:1 GND X13:2 DO02 X13:3 DO03 X13:4 GND X13:5 DO01-C (Pole) X13:6 DO01-NO (NO contact) X13:7 DO01-NC (NC contact) 24VIO Digital outputs Relays 11 30V for on signal -3 +5V for off signal X12:2/DI01 with fixed assignment CW/stop X12:5/DI04 can be used as frequency input X12:6/DI05 can be used as TF input Special characteristics for TF according to DIN EN /trigger value 3kΩ. Auxiliary supply output 24V DC I max = 50mA I max DO02 = 150mA I max DO03 = 50mA V max = 30V I max = 800mA 230V X2 Drive output Motor power 1.7A Table 79: Terminal description of MOVITRAC B [43] 337 P a g e

4 Hardware Modules FBG11B Keypad Module (Refer to FBG11B Keypad Module section in the thesis report for an overview of the functions and some background information) On the keypad module, there are 6 buttons, some menu indicators, a LED screen and a knob. The major functionalities of them are as follows: The LED screen displays the information, status and parameter options. The RUN and STOP buttons are used to activate/deactivate the drive. The left and right arrow buttons are used to enter and exit the menu respectively. The up and down arrow buttons are used to navigate the menu and options. The menu indicator shows the currently active menu. The knob is used to change the speed of the motor during FBG manual operation. [43] Table 80 is the description of the keypad menu. Keypad menu Description Drive status/speed Display the status of MOVITRAC B such as stop, fault and the speed. It could also be programmed to display customized messages. Ramp up time Set the time required in second to ramp up from the current speed to the setpoint speed. Ramp down time Set the time required in second to ramp down from the current speed to the setpoint speed. Fixed setpoint Set the fixed speed setpoints for both parameter sets Maximum speed Define the highest positive speed MOVITRAC B can achieve. Access the parameters of MOVITRAC B. User can use P801 on FBG11B keypad Parameter menu module to switch between short and long parameter lists. The long parameter list covers more parameters than that of short parameter list. However, the most comprehensive parameter list is in MotionStudio. Motor startup menu set 1 Set parameters for motor parameter set 1. Motor startup menu set 2 Set parameters for motor parameter set 2. Data backup Backup data. Activate keypad control and deactivate all the other control sources. (Refer to FBG manual operation MOVIRAC B Standalone Control section for the instruction of FBG manual operation) Frequency display Display the current frequency of the drive. Current display Display the output current of the drive. Table 80: FBG11B keypad module menu description [43] 338 P a g e

5 FSC11B Communication Module (Refer to FSC11B section in the thesis report for an overview of the functions and some background information) Table 81 is the description of terminal functions on FSC11B communication module. Function Terminal Description X46:1 SBus+ X46:2 SBus- X46:3 GND SBus X46:4 SBus high. X46:5 SBus low. X46:6 GND X46:7 24VIO Auxiliary voltage/external voltage supply. X45:H RS485+ RS485 interface X45:L RS485- X45: GND X44 RJ10 service interface for MotionStudio. Termination S1 Termination resistor (120Ω). S2 Reserved. Table 81: Terminal description of FSC11B communication module [43] The termination resistor S1 needs to be turned on at the end of the network only. 339 P a g e

6 Motor Setup The motor setup menu is used to set up the motor parameters and can be accessed on the FBG11B menu. The available settings are listed in Table 82. Parameters Assignments/Ranges SEW: SEW/DT/DV motor Motor NOSEW: Non-SEW motor DRS: SEW DRS motor DRE: SEW DRE motor UF: U/f characteristic curve UFDC: U/f + DC current braking Mode VFC: VFC VFCDC: VFC DC current braking FLY: VFC flying start function HOIST: VFC hoist Power Power in kw. Volt Motor voltage in Volt. Hertz Nominal motor frequency in Hz. RPM Nominal motor speed revolution per minute. Amper Nominal motor current COSPH Phase shift between current and voltage. 4-QAD Yes No MULTI Number of motors for multi-motor drives Table 82: Motor parameter setup on FBG11B keypad module [43] 340 P a g e

7 DFP21B Gateway (Refer to DFP21B Gateway section in the thesis report for an overview of the functions and some background information) The gateway is able to detect the baud rate between 9.6kBaud and 12MBaud. The gateway needs to be powered by 24V DC to operate. X30 terminal is a standard Sub-D9 connection for Profibus connector. Table 83 is the description of the terminals on DFP21B. Terminal Description X24 MotionStudio interface X26:1 SBus+ X26:2 SBus- X26:3 GND X26:4 Reserved. X26:5 Reserved. X26:6 GND X26:7 DC 24V X30 Sub-D9 connection Table 83: Terminal description of DFP21B Profibus gateway [43] Terminal X26:1, X26:2 and X26:3 are used to connect to MOVITRAC B to provide a SBus data transmission. The DFP21B Profibus gateway has 2 LEDs which indicate the status of the card and the Profibus network. The diagnostic descriptions are listed in Table 100 and Table 101. The gateway housing UOH11B provides additional diagnostic functions that are listed in Table 102. [45] Set Profibus Address The Profibus address can be set between 1 and 125 via DIP switches on DFP21B. Table 84 shows the address configuration via DIP switches. DIP switches Address Table 84: DIP switch assignment of DFP21B Profibus gateway [45] Autosetup for Gateway Operation The autosetup function is used to startup the DFP21B card and should remain on. This function is performed at each time the AS DIP switch has been switched from off to on. LED H1 on UOH11B housing will flash a few times after switching on AS indicates searching for units on its SBus hierarchical level. H1 LED remains on if no drive is located or the drive is assigned with an incorrect SBus address or baud rate. The reset must be performed each time when adding or removing the unit. [45] 341 P a g e

8 MotionStudio MotionStudio configuration software is optional for configuring the drive or the gateway, but it provides a user friendly interface for rapid diagnosis and efficient configuration. (Refer to MOVITOOLS MotionStudio section in the thesis report for an overview of the functions and some background information) Configure MOVITRAC B in MotionStudio Either USB11A or UWS21B is required to establish a communication path between the drive and the PC. (Refer to Communication Adaptor section in the thesis report for an overview of the functions and some background information) For USB11A, connect the USB side of the USB11A adapter to PC and the RS485 side to X44 terminal on FSC11B module with a RJ10 connector cable. For UWS21B, connect the RS232 side of the UWS21B adapter to PC and the RS485 side to X44 terminal on FSC11B module with a RJ10 connector cable. Open MOVITOOLS MotionStudio and create a project (Figure 286). Figure 286: Project selection window in MotionStudio 342 P a g e

9 From the toolbar, click Configure communication connections. Only leave one communication connection if others does not preset. Choose Serial from the drop down list and click Edit button (Figure 287). Figure 287: Communication connection selection in MotionStudio Select USB COM port if using USB11A or certain COM port if using UWS21B. Leave the Baud rate as AUTO, then click OK (Figure 288). Figure 288: USB (left) and RS232 (right) communication setting in MotionStudio After choosing the communication medium, click Start network scan from the toolbar to start to scan for devices. After the scan finished, the drive should appear under the Serial hierarchy in the Network window (Figure 289). Figure 289: Detected drive under the communication port in MotionStudio 343 P a g e

10 The exclamation mark indicates the parameters of the detected MOVITRAC B has not been sent to MotionStudio. Right click on the detected drive and choose Configure device. Enter a name for the unit if necessary and click Finish button. (Figure 290). Figure 290: Drive configuration confirmation window in MotionStudio Figure 291: Drive online configuration completion window in MotionStudio The upload process will complete within a short period of time and click OK to accept the upload (Figure 291). Now the exclamation mark on MOVITRAC B should be disappeared and the drive communication has now been successfully configured. 344 P a g e

11 Online and Offline Tools For the configuration tools in MotionStudio, most of them have 2 states, Online and Offline. Online tools: Any changes made will affect the device directly. In order to transfer the parameter data from the unit to the PC, an upload from device at online is required. Offline tools: Any changes made will be stored in the MotionStudio program only and will not affect the unit. In order to transfer the changes to the unit, a download to device at offline is required. Download, Upload & Synchronize Download function is used to overwrite parameters in the unit and must be performed at offline. Whereas upload function is used to obtain the parameter values from the drive to MotionStudio and must be performed online. The synchronize function is mostly used when updating firmware or replacing units and is available for individual unit or every unit under one node. The synchronize function is a combination of download and upload functions. Read & Write to MOVITRAC B from MotionStudio After the drive is configured, click Switch to online mode from the toolbar to go online. To display the parameter, right click the drive from the Network window, Startup Parameter tree (Online). A new screen will pop up with all the parameters (Figure 292), expand the root directory and double click the subdirectory to view the current values of the parameters. Not all the parameters can be changed dynamically online. To change the numerical value, type the value in the field then press the Enter key on the keyboard. Figure 292: Parameter tree of MOVITRAC B in MotionStudio When need to change some key parameters which are not allowed to change online. An offline download is required. In toolbar, click Switch to offline mode to go offline. Perform any changes required and then in the menu bar, Edit Download parameter sets (Figure 293). Figure 293: Download window in MotionStudio 345 P a g e

12 Startup At offline state, right click on the drive, Startup Startup (Offline) will navigate to a Motor startup screen. One of the parameter sets needs to be chosen (Figure 294). [27] Figure 294: Startup parameter set selection window in MotionStudio 346 P a g e

13 Unit information provides the basic operating information of the current status of the drive and motor (Figure 295). [27] Figure 295: Startup unit information window in MotionStudio In the Commissioning support window, choose Direct input for Commissioning mode (Figure 296). [27] Figure 296: Startup commissioning support selection window in MotionStudio 347 P a g e

14 Since the drive available is only linked to one motor, choose Single drive One motor (Figure 297). [27] Figure 297: Startup motor configuration selection window in MotionStudio Choose Standard (v/f) as the Control mode (Figure 298). [27] Figure 298: Startup control mode selection window in MotionStudio 348 P a g e

15 Select Speed control with 4-quadrant operation for general purpose (Figure 299). [27] Figure 299: Startup operating mode selection window in MotionStudio The motor connected is not available in the listed, so choose Measure (Figure 300). [27] Figure 300: Startup motor type selection window in MotionStudio 349 P a g e

16 Click Start calibration and the status would probably display as Measurement failed after a while. But even it fails, it will not affect the normal operation (Figure 301). [27] Figure 301: Startup motor calibration window in MotionStudio Define the setpoint sources and other parameters. It is recommended to click Accept SEW suggestion to get the default values (Figure 302). [27] Figure 302: Startup application configuration window in MotionStudio 350 P a g e

17 Choose the Minimum/Maximum speed and ramping speed. It is recommended to click Accept SEW suggestion to get the default values (Figure 303). [27] Figure 303: Startup limit set up window in MotionStudio Finally click Load into Unit to download parameters to the drive (Figure 304). [27] Figure 304: Startup download to unit window in MotionStudio After the loading finished, go online by clicking Switch to online mode from the menu bar. Then right click the drive from the Network window, Startup Manual mode (Online) to open the manual mode interface. On the FBG11B keypad module, navigate to the very top level menu. Then press RUN button to enable the drive. 351 P a g e

18 Activate MotionStudio manual control in by clicking Activate manual mode button. Click Start to enable the drive and now the speed and the direction of the motor can be controlled (Figure 305). [27] Figure 305: Manual mode control panel in MotionStudio After working with manual mode, it is compulsory to click the Deactivate manual mode button to terminate the online control (Figure 306). Otherwise the drive will indicate a fault code 43 message on FGB11B keypad module after go offline. [27] Figure 306: Manual control activated interface in MotionStudio 352 P a g e

19 Scope Scope is a build-in oscilloscope program in MotionStudio for SEW drives. It can record the drive response up to 8 channels of analog/digital in realtime. All the data can be represented in a curve form and displayed on a graph with customized colours and adjustable divisions. [43] Click Switch to online mode to go online first. In the Network window, right click the drive, Diagnostic Scope (Online). From the toolbar, click Recorder settings. In the pop up window, choose Empty record if no template was made previously (Figure 307). Figure 307: Record selection window in MotionStudio 353 P a g e

20 User can choose up to 8 parameters to record and the recording will start as soon as the Start button has been pressed. The recording will be stopped when the trigger is activated. The trigger can be controlled via different signal sources such as manual, analog or digital channels (Figure 308). Figure 308: Scope configuration window in MotionStudio Since the maximum number of samples it can hold is limited to 2048 samples, the sample time needs to be carefully selected. By default, it is set to 1ms which corresponds to a maximum recording time of 2048ms. As the sample time increases, the maximum recording time will increase as well. After the recording is finished, press Load button to display the recorded data. 354 P a g e

21 Figure 309 is a ramping recording with sample time of 1ms for 3 parameters which are actual speed, output current and actual frequency. Figure 309: Scope window with active parameters 355 P a g e

22 Comparison The comparison function is used to quickly find out different parameter settings between 2 units. Right click a unit in the Network window and choose Comparison. Select the desired unit from the drop down list for Source 1 and Source 2. Two options are available, one is to use the project data and the other one is to upload the online data. In order to use the filter function, press the down arrow button and tick the desired paramters. Finally, click Compare button to process the comparision (Figure 310). Figure 310: Comparison of parameters from 2 drives in MotionStudio 356 P a g e

23 MOVITRAC B Standalone Control For safety reason, except for FBG manual control, Enable/stop and either CW or CCW options must be assigned to binary inputs (either actual or virtual) and set to ON in order to enable the drive. [47] Keypad Control To start the motor, navigate the keypad menu to FBG manual operation first. (Refer to FBG11B Keypad Module section for keypad module operation instructions) The FBG manual operation icon should be highlighted. Press right arrow button to enter manual operation. Now the FBG manual operation symbol should be flashing. Finally press the RUN button to start the drive. The knob on the FBG11B keypad module can now be used to control the speed. The minimum and maximum speeds are determined by P301 Minimum speed and P302 Maximum speed respectively. P122 Direction of rotation FBG manual operation can be used to set the direction configuration which applies to the knob on FGB11B keypad module. To stop the motor, simply press the STOP button. P760 locking RUN/STOP keys does not have any effect during manual operation. Terminal Control Terminal control refers to the digital input control. To enable terminal control, P101 Control signal source needs to be set to Terminals and P100 Setpoint source needs to be set to something like Bipolar or Unipolar to eliminate the external control. P601 to P608 are the places to assign individual function to the digital input terminals. Make sure to exit FBG manual operation if currently in (FBG manual operation will limit to the keypad control). Then press RUN button on the FBG11B keypad module to activate terminal control. (Refer to Table 79 for an outline of all the terminals) External Potentiometer Control In order to use an external potentiometer to control the motor, wire a potentiometer to the drive terminal AI11 and GND. The potentiometer is expected to have a range from 0V to 10V. (Refer to Table 79 for an outline of all the terminals) Set P100 Setpoint source to Fixed setpoint + AI01 will generate a resultant speed of the summation of the fixed setpoint such as n11/n21 and the analog input value. AI from 0 to 10V corresponds to 0% to 100% of the maximum speed. For example, if the setpoint is 100 RPM and the potentiometer reading is 5V with the maximum speed of 1000RPM, then the final setpoint will be V 1000 = 600RPM. 10V Choose Fixed setpoint * AI01 for P100 Setpoint source will obtain a resultant speed of the multiplication of the fixed setpoint such as n11/n21 and the analog input reading. AI from 0 to 10 V corresponds to 0% to 100% of the setpoint speed. For example, if the setpoint is 100RPM and the potentiometer reading is 5V with the maximum speed of 1000RPM. Then the final setpoint will be V 100% = 500RPM. 10V P101 Control signal source needs to be set to Terminals to activate potentiometer control. Make sure to exit FBG manual operation if currently in (FBG manual operation will limit to the keypad control). Then press RUN button to activate external potentiometer control. 357 P a g e

24 Fieldbus Control Communication between Gateway and MOVITRAC B Firstly, connect terminal 1, 2 and 3 (High, Low and GND) from Gateway X26 to terminal 1, 2 and 3 (High, Low and GND) from MOVITRAC B X46 respectively with a RS485 cable or Profibus cable. The gateway needs to be powered by 24V DC at pin X26:7 and X26:6. If 2 or more drives are present, connect terminal 4, 5 and 6 (High, Low and GND) of the previous MOVITRAC B to terminal 1, 2 and 3 (High, Low and GND) of the next MOVITRAC B. (Refer to Table 83 for an outline of DFP21B terminals) Plug USB11A/UWS21B into each MOVITRAC B and configure them in MotionStudio if MotionStudio is available. Otherwise set up the parameters via FBG11B keypad module. Set P880 SBus protocol to MoviLink with different SBus addresses other than 0 for each drve. (address 0 is always reserved for the gateway and valid SBus address for the drive is from 1 to 64). The SBus baud rate of the drives must be the same as the gateway, otherwise they will not be recognized by the gateway. Now unplug USB11A/UWS21B connection from the drive and plug into DFP21B and perform a network scan. The drives should appear under the SBus hierarchy. If MotionStudio is not available, the steps below in MotionStudio can be skipped as MotionStudio only provides an interface for gateway diagnosis. The exclamation mark indicates the parameters of the detected gateway has not been sent to MotionStudio (Figure 311). Reset the Autosetup DIP switch on the gateway and wait until H1 LED stays off. (Refer to Autosetup for Gateway Operation section for some information about AS DIP switch) Figure 311: Detected gateway under the communication port in MotionSutdio Right click on the detected gateway and choose Configure device. Enter a name for the gateway if necessary and click Finish button (Figure 312). Figure 312: Gateway online configuration confirmation window in MotionStudio 358 P a g e

25 The upload process will complete within a short period of time and click OK to accept the upload (Figure 313). Figure 313: Gateway online configuration completion window in MotionStudio After the gateway configuration, the exclamation mark on the gateway should be disappeared which indicates that the communication between the gateway and the drives have now been configured correctly (Figure 314). Figure 314: Detected drives under communication port 359 P a g e

26 Gateway Profibus Communication First of all, connect PLC and DFP21B with Profibus connectors and switch on the termination switch S1 for the last drive only. Also make sure the Profibus signal is terminated properly on each end of the network. Make sure GSD file sew_6009.gsd is installed in TIA Portal, then locate the gateway station in TIA Portal Hardware Catalog (Figure 315). Figure 315: DFP21B station in Hardware Catalog in TIA Portal If the master Profibus network has been established earlier, drag the gateway station into the Network view and join gateway into the Profibus subnet (Figure 316). Assign a Profibus address to the gateway based on the DIP switches setting. (Refer to Table 84 for setting Profibus address for DFP21B) Figure 316: Assign DFP21B station to the master PLC in TIA Portal Replace the empty module of Param-Channel in the module rack with the Parameter channel slave module from Catalog if necessary. At least one of the AS slave module needs to be placed on the rack (Figure 317). Figure 317: Parameter channel and AS slave modules in the module rack in TIA Portal Perform a download to PLC and the BUS FAULT LED on the gateway should be off once the download finished which indicates that the Profibus master has been recognized. 360 P a g e

27 Go online in TIA Portal will see there is a bit error displayed on the diagnostic icon (Figure 318). It is because PROFIsafe-Channel slave module is filled with an empty module. The PROFIsafe-Channel can only be filled with F-Module I/O slave module, which is not supported by the current PLC. Thus, this error could not be eliminated (Figure 319). However, this error will not affect the normal operation of the Profibus data exchange. Figure 318: Online network view of DFP21B in TIA Portal Figure 319: Online slave module status in TIA Portal If the communication between the gateway and the drive already exists (Refer to Communication between Gateway and MOVITRAC section for communication configuration), go online in MotionStudio and right click gateway in the Network window, Startup DFx Gateway configurator (Online). A green tick should be present on the left hand side (Figure 320). If any units have been added or removed, the AS DIP switch needs to be reset. (Refer to Autosetup for Gateway Operation section for some information about AS DIP switch) Figure 320: Gateway online parameters view in MotionStudio 361 P a g e

28 Click Process data configuration tab to show all the configured units (Figure 321). Figure 321: Gateway online communication with 2 drives in MotionStudio After the communication between Profibus master, gateway and the drive has been established, change parameter P100 Setpoint source and P101 Control signal source to SBus 1 for each of the drive in the network. This allows gateway to pass the Profibus control signals from the master to the drive. P876 Enable PO data needs to be set to Yes to allow PO data. The data exchange between Profibus master and the drive can be monitored via Process data monitor tab in the DFx Gateway Configurator (Figure 322). Figure 322: Gateway online process data monitor view 362 P a g e

29 Gateway Slave Modules (Refer to Slave Modules section in the thesis report for some background and the slave module structure) F-Module I/O Slave Module This slave module is used for PLC with PROFIsafe profile only. Leave an empty module on the rack for PROFIsafe channel to skip it. [23] Parameter Channel Slave Module The structure of the Parameter Channel slave module is shown in Table 85. (Refer to Sample Code section for some data exchange examples) Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Management (Table 86) Subindex Index high Index low Data 4 Data 5 Data 6 Data 7 Table 85: Parameter channel slave module data structure [45] Management Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Status Bit Handshake Bit Data length Service Identifier (Table 87) 0000: No service 0: No error during 00: 1 Byte 0001: Read parameter Must Toggle on every service execution 01: 2 Bytes 0010: Write parameter new service in cyclical 1: Error during 10: 3 Bytes 0110: Read default transmission. service execution 11: 4 Bytes 0111: Read scale 1000: Read attribute Table 86: Parameter channel slave module management byte data structure [45] Status Bit The status bit is an important diagnostic bit that provides the feedback information about the data exchange service. [45] Handshake Bit Bit 6 of the management byte is known as a handshake bit. The state of the handshake bit changes to trigger the data exchange service. [45] Data Length Data length indicates the desired data length that needs to be transferred per service. It should always be set to 4 bytes. [45] 363 P a g e

30 Service Identifier The service identifier determines the type of the data exchange service. Service identifier Description No service No data is required to transfer. Read parameter Read a value from gateway. Write parameter Write value to gateway which will be stored non-volatile. Read default Read the factory setting value of a certain parameter from gateway. Read scale Read the scaling of the parameter. Read attribute Read the access attributes and also the index of the next available parameter. Table 87: Parameter channel slave module service identifier description [47] Read Scale The read scale provides a way to determine the scaling of the parameter. It consists of a measurement index and a conversion index. Byte 4 Byte 5 Byte 6 Byte 7 Reserved Measurement index Conversion index Table 88: Parameter channel slave module read scale data structure [47] Measurement Index The measurement index provides a pure number to describe the actual value without any multiplier. [47] Conversion Index The conversion index provides multiplier associated with the measurement index to convert the actual value into SI units. [47] Read Attribute The read attribute service allows the master controller to access attributes and the index of the next available parameter. Byte 4 Byte 5 Byte 6 Byte 7 Next available index Access attributes (Table 90) Table 89: Parameter channel slave module read attribute data structure [47] Byte 6 Bits Byte 7 Bits Assignments 0 0: Parameter does not allow write access 1: Parameter allows write access 1 0: Parameter is not permanently save on EEPROM 1: Parameter is permanently saved on EEPROM 2 0: Factory setting does not overwrite RAM value 1: Factory setting overwrites RAM value 3 0: Factory setting does not overwrite EEPROM value 1: Factory setting overwrites EEPROM value 4 0: EEPROM value is not valid after initialization 1: EEPROM value is valid after initialization 5 0: Controller inhibit condition is necessary for write access 1: Controller inhibit condition is not necessary for write access 6 0: Password not required 1: Password required : Parameter is generally valid 01: Parameter is assigned to parameter set 1 10: Parameter is assigned to parameter set 2 11: Parameter is assigned to both parameter sets 9-15 Reserved. Table 90: Parameter channel slave module access attributes assignments [47] 364 P a g e

31 Subindex Byte 1 Subindex is reserved and should be kept as 00 hex. [45] Index Bytes Index Byte 2 and 3 define certain parameter which is to be read or written by the master. The parameter index of the gateway can be obtained from MotionStudio while mouse over parameters. [45] Data Bytes Byte 4 to byte 7 contain either input data or output data depending on the type of the service identifier. [45] Incorrect Service Execution Whenever the status bit shows 1, an error has occurred during the data exchange. In this case, Byte 4 to Byte 7 will now send back the error information in a structured format instead. Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Error class Error Add. Code high Add. Code low Management Subindex Index high Index low (Table 103) code (Table 104) (Table 104) Table 91: Parameter channel slave module incorrect service execution data structure [45] 365 P a g e

32 AS Slave Modules The PD assignments can be assigned in P870 P875. (Refer to Parameter List section for available assignments) AS DIP switch on the gateway needs to be reset each time the process data parameter assignment changes. (Refer to Sample Code section for some data exchange examples) Control Word (Refer to Control Word section in the thesis report for some background) The control word has a length of 16 bits. The 8 least significant bits are known as basic control block and have identical definition for both control word 1 and 2 which control the most important drive behaviours. The 8 most significant bits are different for control word 1 and 2. Table 92 and Table 93 show the structure of the control word 1 and 2 respectively. Control Word 1 Bit Function Description Assignment Quickly stop the motor by 0: Enable 0 Controller inhibit disabling output power and 1: Controller inhibit set it to high impedance. 1 Rapid stop Generate a brake from the drive with a rapid ramp set up in P136/P146 Stop ramp. 0: Rapid stop 1: Enable 2 Stop Stop the motor with the stop 0: Stop ramp. 1: Enable 3 Hold control Trigger a stop at integrator 0: Active ramp with subsequent hold 1: Not active control. 4 Ramp generator selection Select integrator ramps. 0: Integrator 2 1: Integrator 1 5 Parameter set switchover Switch between different 0: Parameter set 1 parameter sets. 1: Parameter set 2 6 Reset Reset the fault. 0: Not active 1: Reset pending fault 7 Reserved Set reversed bit to zero. N/A 8 Direction of rotation for motor Select the rotation for motor 0: CW potentiometer potentiometer. 1: CCW 00: No change 9 Motor potentiometer Select the potentiometer 01: Down & acceleration/deceleration acceleration or deceleration. 10: Up 10 11: No change 11 & 12 Selection of the internal fixed setpoint n11 n13 or n21 n23 13 Fixed setpoint switch over Select the setpoints. Switch setpoints between parameter set 1 and Reserved Set reversed bit to zero. N/A 15 Reserved Set reversed bit to zero. N/A Table 92: AS slave module control word 1 data structure [47] 00: Speed setpoint via process output data word 2 01: Internal setpoint n11 (n21) 10: Internal setpoint n12 (n22) 11: Internal setpoint n13 (n23) 0: Fixed setpoints of the active parameter set selectable via bit 11/12 1: Fixed setpoints of the other parameter set selectable via bit 11/ P a g e

33 Control Word 2 Bit Function Description Assignment Quick stop the motor by disabling 0: Enable 0 Controller inhibit output power and set it to high 1: Controller inhibit impedance. 1 Rapid stop Generate a brake from the drive with a rapid ramp set up in P136/P146 Stop ramp. 0: Rapid stop 1: Enable 2 Stop Stop the motor with the stop ramp. 0: Stop 1: Enable 3 Hold control Trigger a stop at integrator ramp with 0: Active subsequent hold control. 1: Not active 4 Ramp generator selection Select integrator ramps. 0: Integrator 2 1: Integrator 1 5 Parameter set switchover Switch between different parameter 0: Parameter set 1 sets. 1: Parameter set 2 6 Reset Reset the fault. 0: Not active 1: Reset pending fault 7 Reserved Set reversed bit to zero. N/A 8 Virtual binary input DI10 9 Virtual binary input DI11 10 Virtual binary input DI12 11 Virtual binary input DI13 Depending on the virtual binary input Refer to Parameter List section for 12 Virtual binary input DI14 assignments. available digital input assignments. 13 Virtual binary input DI15 14 Virtual binary input DI16 15 Virtual binary input DI17 Table 93: AS slave module control word 2 data structure [47] 367 P a g e

34 Status Word (Refer to Status Word section in the thesis report for some background) The status word has a length of 16 bits. The 8 least significant bits are known as basic status block and have identical definition for both status word 1 and 2 which describes the most important drive statuses. The 8 most significant bits are different for status word 1 and 2. Table 94 and Table 95 show the structure of the status word 1 and 2. Status Word 1 Bit Function Description Assignments 0 Output stage Display the status of the drive. 0: Inhibited 1: Enabled 1 Inverter ready Indicate whether the drive is 0: Not ready ready. 1: Ready 2 PO data Indicate whether PO data is 0: Disabled enabled. 1: Enabled 3 Current ramp set Display the current ramp 0: Integrator 1 selection. 1: Integrator 2 4 Current parameter set Display the current parameter 0: Parameter set 1 set. 1: Parameter set 2 5 Fault/warning Indicate whether the drive has a 0: No fault fault or warning. 1: Fault/warning pending 6 CW limit switch Show the status of the CW limit 0: Inactive switch. 1: Active 7 CCW limit switch Show the status of the CCW limit 0: Inactive switch. 1: Active 8-15 Unit Status/ Fault number Display either unit status or fault number depending on bit 5. Table 94: AS slave module status word 1 data structure [47] Bit 5 = 0: Unit status (Table 96) Bit 5 = 1: Fault number (Table 99) 368 P a g e

35 Status Word 2 Bit Function Description Assignment 0 Output stage Display the status of the drive. 0: Inhibited 1: Enabled 1 Inverter ready Indicate whether the drive is ready. 0: Not ready 1: Ready 2 PO data Indicate whether PO data is enabled. 0: Disabled 1: Enabled 3 Current ramp generator set Display the current ramp selection. 0: Integrator 1 1: Integrator 2 4 Current parameter set Display the current parameter set. 0: Parameter set 1 1: Parameter set 2 5 Fault/warning Display whether the drive has a fault or 0: No fault warning. 1: Fault/warning pending 6 CW limit switch Indicate the status of the CW limit switch. 0: Inactive 1: Active 7 CCW limit switch Indicate the status of the CCW limit 0: Inactive switch. 1: Active 8 Virtual binary output DO10 9 Virtual binary output DO11 10 Virtual binary output DO12 11 Virtual binary output DO13 12 Virtual binary output DO14 13 Virtual binary output DO15 14 Virtual binary output DO16 15 Virtual binary output DO17 Depend on the virtual binary output assignments. Table 95: AS slave module status word 2 data structure [47] Refer to Parameter List section for available digital output assignments. Unit Status Unit status No. Description 0 Not ready. 1 Controller inhibit. 2 Not enable. 3 Standstill current active, not enable. 4 Enable. 8 Factory setting is active. Table 96: AS slave module unit status/fault number assignments [47] 369 P a g e

36 Diagnostic Code FBG11B Keypad Module FBG11B Display FBG11B LED Description Speed Solid green Enabled. Speed flashes Green rapid flashing Enable at current limit. Dc Green slow flashing Standstill current. Stop Solid yellow Disabled. Set Yellow rapid flashing Factory setting. Off Yellow rapid flashing Controller inhibit. 24V flashing Yellow slow flashing 24V operation. V flashing or 24V flashing Yellow slow flashing Safe stop. FGB manual operation symbol or stop is flashing Yellow on long, off briefly FBG manual mode is activated. Error 43/47 Green/yellow flashing Timeout. Error 97 Red/yellow flashing Copy. Error 10/17 24/25/32/37/38/56/77/80/94 Solid red System error. Error 4/6/7 Red slow flashing Over voltage/phase failure. Error 1/3/11/44/84 Red rapid flashing Overload. Error 8/26/34/81/82 Red flashing 2 Monitoring. Error 31/84 Red flashing 3 Motor protection. Table 97: FBG11B keypad module diagnostic display description [43] Return Code No. Designation Description 19 Parameter lock activated Parameters cannot be changed. 20 Factory setting in progress Parameters cannot be changed. 23 Option card missing The option card required for the function is missing. 27 Option card missing The option card required for the function is missing. 28 Controller inhibit required Controller inhibit required. 29 Invalid value for parameter Invalid value for parameter FBG manual operation selection invalid as PC is in active manual operation 32 Enable You cannot perform this function in Enable status. 34 Error during execution Error while saving in FBG11B Startup not performed with FBG. Perform FGB startup with MotionStudio or select a new motor. 38 FB11B incorrect data set Stored data set does not match the unit. Table 98: FBG11B keypad module diagnostic return code description [43] 370 P a g e

37 Fault Number No. Designation Description 00 No error N/A 01 Overcurrent Short circuit on output. Switching on output. Motor too large. Faulty output stage. 03 Ground fault Ground fault in motor. Ground fault in inverter. Ground fault in the motor supply lead. Overcurrent. 04 Brake chopper Too much regenerative power. Braking resistor circuit interrupted. Short circuit in the braking resistor circuit. Brake resistor resistance too high. Brake chopper defective. Ground fault. 06 Mains phase Phase failure. Supply voltage too low. 07 DC link voltage DC voltage too high. Ground fault. 08 Speed Monitoring The setpoint speed is too high. 09 Startup Inverter not started yet. Unknown motor selected. 10 IPOS-ILLOP Wrong command during program execution. Incorrect conditions during program execution. Function does not exist. 11 Over temperature Thermal overload of inverter System malfunction Inverter electronics is faulty possibly due to EMC influence. 25 EEPROM Fault while accessing EEPROM. 26 External terminal Read in external fault signal via programmable input. 31 TF/TH sensor tripped Motor too hot, TF sensor has tripped. TF sensor of motor not connected or connected incorrectly Connection of MOVITRAC B and TF on motor interrupted 32 IPOS index overflow Programming principles violated leading to internal stack overflow. 34 Ramp timeout Set ramp time exceeded. If remove inhibit and the drive exceeds the stop ramp time t13 by a certain time, the inverter will signal F Ex-e protection operating mode Wrong operating mode selected. Non-permitted parameter set. No Ex-e motor taken into operation. Incorrectly parameterized frequency points. Current limits not set correctly. 36 Option missing Type of option card not allowed. Setpoint source, control signal source or operating mode not permitted for this option card. Required option missing. 37 System watchdog Fault in system software sequence. 38 System software System malfunction. 43 RS485 timeout Connection between inverter and PC interrupted. 44 Unit utilization Unit utilization (Ixt value) exceeded. 45 Initialization Error during initialization. 47 System bus 1 timeout Fault during communication via system bus. 371 P a g e

38 77 IPOS control word System malfunction. 80 RAM test Internal unit fault, RAM defective. 81 Start condition Rated motor power too small in relation to rated inverter power. Motor cable cross section too small. 82 Open output ( VFC hoist mode) 2 or all output phases interrupted. Rated motor power too small in relation to rated inverter power. 84 Motor protection Motor utilization too high. 94 EEPROM checksum Defective EEPROM. 97 Copy error Parameter module is removed during copying process Switching off/on during copying process 98 CRC error flash Internal unit fault flash memory defective. 100 Vibration/warning Vibration sensor warning. 101 Oscillation fault Vibration sensor signals fault. 102 Oil aging/warning Oil aging sensor warns. 103 Oil aging/fault Oil aging sensor signals fault. 104 Oil aging/over temperature Oil aging sensor signals over temperature. 105 Oil aging/ready signal Oil aging sensor is not ready for operation. 106 Brake wear Brake lining worn down. 110 Ex-e protection fault Duration of operation below 5 Hz exceeded. 113 Analog input open circuit AI1 analog input open circuit. 116 Timeout MOVI-PLC fault MOVI-PLC communication time out. Table 99: FBG11B keypad module diagnostic fault number description [43] 372 P a g e

39 DFP21B RUN LED RUN Description Green Profibus hardware is OK. Orange Booting in progress. Off Hardware defect in the bus electronics. Flashes 2Hz The Profibus address is either set to 0 or higher than 125. Flashes 1Hz Display only, no error. Table 100: DFP21B Profibus gateway RUN diagnostic LED behaviour description [45] BUS FAULT LED BUS FAULT Description Connection to the Profibus master has lost. The Profibus baud rate is not detected by the card. Red Bus interruption. Profibus master not in operation. Off The card is now exchanging data with the Profibus master. The card has not been addressed by the Profibus master, but it has detected the baud rate. Flashing The card has not been configured properly in the Profibus master. Table 101: DFP21B Profibus gateway BUS FAULT diagnostic LED behaviour description [45] UOH11B H1 Description Red Gateway is not configured correctly or one of the VSD is inactive. Off Gateway has been correctly configured. Flashing SBus is been checked by the gateway. Table 102: UOH11B housing H1 diagnostic LED behaviour description [45] H2 is reserved. 373 P a g e

40 Error Code for Parameter Channel Slave Module Error Class Class (hex) Designation Description 1 vfd state Status error of the virtual field device. 2 application reference Error in the application program. 3 definition Definition error. 4 resource Resource error. 5 service Fault during service execution. 6 access Access error. 7 ov Error in the object directory. 8 other Other errors. Table 103: Parameter channel slave module error class description [45] Error Class 8 Additional Code Add. code high Add. code low Description No error Illegal parameter index Function/parameter not implemented Read access only Parameter lock is active Factory setting is active Value for parameter too large Value for parameter too small Required option card missing for this function/parameter Error in system software Parameter access via RS-485 process interface on X13 only. 00 1A Parameter access via RS-485 diagnostic interface only. 00 1B Parameter is access-protected. 00 1C Control inhibit required. 00 1D Invalid value for parameter. 00 1E Factory setting was activated. 00 1F Parameter was not saved in EEPROM Parameter cannot be changed with enabled output stage. Table 104: Parameter channel slave module error class 8 additional code description [45] 374 P a g e

41 Sample Code Sample Code of PI and PO for 2 Drives Figure 323: Online sample code PI and PO process data of AS slave module data exchange 375 P a g e

42 Drive1 Read 0407 hex from Status word 1 (PI1) 0407 hex = 0000_0100_0000_0111 bin, indicates drive 1 is currently enabled and ready with PO activated. Read 009E hex from Output current (PI2) 009E hex = 158 dec, 158 dec 0.1 = 15.8% I N. This indicates that the active current is now 15.8% of the rated current. Read F63C hex from Actual speed (PI3) F63C hex = dec, dec hex = dec dec = 2500 dec = 2500RPM CCW. Only write enable to Control word 1 (PO1) 0000_0000_0000_0110 bin = 0006 hex. Write CW 2000 RPM to Max speed (PO2) ( 2000 ) = 10000dec = 2710hex. 0.2 Write CCW 500 RPM to Setpoint speed (PO3) ( 500 ) = 2500dec, 10000hex 2500dec = 65536dec dec = dec = F63C hex. Drive 2 Read 8507 hex from Status word 2 (PI1) 8507 hex = 1000_0101_0000_0111 bin, indicates drive 2 is currently enabled and ready. PO is also activated and DO10, DO12 and DO17 are on. Read E000 hex from Actual speed % (PI2) E000 hex = dec, dec hex = dec dec = 8192 dec, 8192 dec 100 = 50%. This indicates that the current speed is 50% of the maximum speed which is CCW. Read FFBF hex from Active current (PI3) FFBF hex = dec, dec hex = dec dec = 65 dec, 65 dec 0.1 = 6.5% I N. This indicates that the active current is now -6.5% of the rated current. Write enable and on to virtual binary inputs DI10, DI15 and DI17 to Control word 2 (PO1) 1010_0001_0000_0110 bin = A106 hex. Write 50% (CCW) to Set speed % (PO2) 50 ( ) = 8192dec, 10000hex 8192dec = 65536dec dec = dec = E000 hex. Write 5s to Ramp (PO3) 5s = 5000ms = 5000 dec = 1388 hex. 376 P a g e

43 Read Parameter Toggle Sample Code Figure 324: Online sample toggle code for read parameters of AS slave module data exchange Send 0011_0001 bin = 31 hex to Management Byte Toggle 1 for Read parameter value. Send 0111_0001 bin = 71 hex to Management Byte Toggle 2 for Read parameter value. Sample Code to Read Parameter Value Figure 325: Online sample code read parameters of AS slave module data exchange Send 00 hex to Subindex Default. Send 21 hex to Index high and 06 hex to Index low gives 2106 hex = 8454 dec Fieldbus address Read 04 hex = 4 dec from Data 7 Fieldbus address is 4. Read 71 hex from Feedback Read successful. 377 P a g e

44 Write Parameter Toggle Sample Code Figure 326: Online sample toggle code for write parameters of AS slave module data exchange Send 0011_0010 bin = 32 hex to Management Byte Toggle 1 for Write parameter value. Send 0111_0010 bin = 72 hex to Management Byte Toggle 2 for Write parameter value. Sample Code to Write Parameter Value Figure 327: Online sample code write parameters of AS slave module data exchange Send 00 hex to Subindex Default. Send 21 hex to Index high and 9B hex to Index low gives 219B hex = 8603 dec SBus baud rate. Write 3 dec = 03 hex to Data 7 Set SBus baud rate to 1Mbaud. Read 32 hex from Feedback Write successful. 378 P a g e

45 Read Default Toggle Sample Code Figure 328: Online sample toggle code for read default parameter value of AS slave module data exchange Send 0011_0110 bin = 36 hex to Management Byte Toggle 1 for Read default value. Send 0111_0110 bin = 76 hex to Management Byte Toggle 2 for Read default value. Sample Code to Read Default Value Figure 329: Online sample code read default parameter value of AS slave module data exchange Send 00 hex to Subindex Default. Send 21 hex to Index high and A2 hex to Index low gives 21A2 hex = 8610 dec Fieldbus timeout response. Read 0A hex = 10 dec from Data 7 Stop drive via PO1. Read 36 hex from Feedback Read successful. 379 P a g e

46 Read Parameter Attribute Toggle Sample Code Figure 330: Online sample toggle code for read parameter attributes of AS slave module data exchange Send 0011_1000 bin = 38 hex to Management Byte Toggle 1 for Read attribute value. Send 0111_1000 bin = 78 hex to Management Byte Toggle 2 for Read attribute value. 380 P a g e

47 Sample Code to Read Parameter Attributes Figure 331: Online sample code read parameter attributes of AS slave module data exchange Send 00 hex to Subindex Default. Send 21 hex to Index high and 03 hex to Index low gives 2103 hex = 8451 dec PD configuration. Read 21 hex from Data 4 and 04 hex from Data 5 gives 2104 hex = 8452 dec Index for the next available parameter. Read 00 hex from Data 6 and 04 hex from Data 7 gives 0004 hex = 0000_0000_0000_0100 bin Factory setting overwrites RAM value. Read 38 hex from Feedback Read successful. 381 P a g e

48 DFP21B Parameter list The purple P indicates the particular parameter is read only. Group 0 Display Values (Read Only) Status Display Address Index (dec) Name Description Assignments/Ranges P Fault status Display the fault status. Read only P Operating hours [h] Display the operating hours [h] Table 105: Status display parameters of DFP21B [45] Unit Data Address Index (dec) Name Description Assignments/Ranges P Unit type Display the unit type. Read only P Basic unit firmware Display the firmware version. Read only Table 106: Unit data parameters of DFP21B [45] Bus Diagnostic Address Index (dec) Name Description Assignments/Ranges P PD configuration Display the process data configuration. Read only P Fieldbus type Display the fieldbus type. Read only P Fieldbus baud rate [kbaud] Display the fieldbus transmission rate. Read only P Fieldbus address Display the fieldbus address. Read only Table 107: Bus diagnostic parameters of DFP21B [45] 382 P a g e