MCD 3000 Series Soft Starters to PROFIBUS Gateway

MCD 3000 Series Soft Starters to PROFIBUS Gateway
MCD – PROFIBUS GATEWAY
MCD-PROFIBUS Gateway
for MCD3000 Series Soft Starter
and MCD Remote Operator
P/N FS-1135
DANFOSS P/N 175G0092
User Manual
Ver. 2.03
10 August 2006
© Copyright 2002 Fieldbus Specialists
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REVISION NOTES
Index
Date
Chapt
er
Author
Rev.
Revision note
1
04-Feb-2002
All
AMcN
1.0
Created
2
11-Feb-2002
All
AJ
1.1
Various corrections
3
10-Mar-2002
All
AJ
1.2
Extended indications for invalid PROFIBUS
address
4
14-Mar-2002
2.6.2, 7
AJ
1.3
Local/Remote setting recommendations,
corrections to Specifications
5
4-April-2002
2.6.1
AKJ
1.4
Wiring diagrams added, mapping of read
memory corrected
6
5-MAY-2002
All
AmcN,
AJ
1.5
Unified format, added functions to handle
comm. breakdown
7
25-OCT-2002
AJ
1.6
Added comments related to Siemens S7
PLC
8
1-OCT-2003
JP
1.7
Added comments re. firmware version 2.02
and code compliance with Danfoss
manual AMB00000 Rev. G
9
9-OCT-2003
JP/AJ
1.8
Modified to reflect compliance with
AMB00000 Rev. G
10
10-OCT-2003
JP
1.9
Note re. byte sequencing in 2.10
11
20-DEC-2004
AJ
1.10
Max. no of MCD300 corrected to 23
12
08-MAR-2006
AJ
2.00
New version of protocol, firmware 3.xx
13
10-MAY-2006
AJ
2.01
Correction of minor errors, changes to
drawings
14
22-JUN-2006
AJ
2.02
Numerous corrections
15
10-AUG-2006
AJ
2.03
Removal of references to “preset”
TECHNICAL SUPPORT
In case of any questions or problems, please contact Fieldbus Specialists on
[email protected]
We will endeavour to reply immediately.
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PREFACE
The data and illustrations in this manual are not binding.
Fieldbus Specialists reserve the right to modify our products in
line with our policy of continuous product development. The
information in this manual is subject to change without notice
and should not be considered as a commitment by Fieldbus
Specialists.
Fieldbus Specialists assume no responsibility for any errors that
may appear in this document.
Although this product has been developed with great care
and extensively tested, Fieldbus Specialists cannot guarantee
the suitability of this product for any purpose. Warranty claims
shall be limited to the right to require rectification of faults.
Liability for any damages, which may have arisen from the use
of this product or its documentation, shall be limited to cases of
intent.
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CONTENTS
1
INTRODUCTION ............................................................................................................................. 7
1.1
1.2
2
IMPORTANT USER INFORMATION ............................................................................................................... 7
GENERAL .................................................................................................................................................. 7
INSTALING THE GATEWAY .......................................................................................................... 9
2.1
2.2
2.3
2.4
2.5
GATEWAY CONNECTION DIAGRAM............................................................................................................ 9
FRONT PANEL ......................................................................................................................................... 10
INSTALLATION SEQUENCE ....................................................................................................................... 12
POWER CONNECTION .............................................................................................................................. 12
PROFIBUS CONNECTION ....................................................................................................................... 13
2.5.1
Cabling ..........................................................................................................................................13
2.5.2 GATEWAY CONFIGURATION ................................................................................................................... 14
2.6 MCD CONNECTION ................................................................................................................................. 15
2.6.1
2.6.2
3
PROGRAMMING THE MASTER CONTROLLER ........................................................................ 20
3.1
3.2
3.3
3.4
3.6
3.7
4
Cabling ..........................................................................................................................................15
MCD device configuration ........................................................................................................17
GSD FILE ................................................................................................................................................ 20
DECLARING MODULES ............................................................................................................................ 20
SETTING PROFIBUS PARAMETERS ........................................................................................................ 21
MASTER-SLAVE DATA EXCHANGE .......................................................................................................... 23
DATA READ AREA ................................................................................................................................... 24
ISSUING COMMANDS .............................................................................................................................. 27
OPERATION OF THE GATEWAY ................................................................................................ 31
4.1
4.2
4.3
SCANNING SLAVES .................................................................................................................................. 31
SCANNING TIMES .................................................................................................................................... 31
OFFLINE SLAVES ..................................................................................................................................... 33
5
SPECIFICATIONS ......................................................................................................................... 34
6
TROUBLESHOOTING .................................................................................................................. 35
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Table List
Table 1 – LED Indication .......................................................................................................................................11
Table 2 – PROFIBUS socket pin assignment .......................................................................................................13
Table 3 – RS-485 pin assignment .........................................................................................................................15
Table 4 – Soft starter Local/Remote modes..........................................................................................................18
Table 5 – Soft starter RS-485 baud rate values ....................................................................................................18
Table 6 – Soft starter address on RS-485 network ...............................................................................................18
Table 7 – MCD Remote Operator RS-485 baud rate values .................................................................................19
Table 8 – MCD Remote Operator address on RS-485 network ............................................................................19
Table 9 – MCD Remote Operator network protocol ..............................................................................................19
Table 10 – Gateway parameter, RS-485 link baud rate ........................................................................................21
Table 11 – Gateway parameter, gateway operation on communication loss ........................................................22
Table 12 – PROFIBUS Write / Out Memory ..........................................................................................................24
Table 13 – Command result codes .......................................................................................................................24
Table 14 – PROFIBUS Read / In memory.............................................................................................................26
Table 15 – Valid commands..................................................................................................................................27
Table 16 – New Command / Command Acknowledge handshaking ....................................................................29
Table 17 – Result Ready / Result Acknowledge handshaking ..............................................................................29
Table 18 – Scanning cycle length for different baud rates and the number of MCD devices present...................32
Table 19 – Maximum time to detect return of an offline device .............................................................................32
Table 20 – Gateway specifications........................................................................................................................34
Table 21 – Troubleshooting guide.........................................................................................................................35
Figure List
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Typical diagram of a PROFIBUS network, a gateway and an RS-485 sub-network. ..............................9
Gateway front panel ..............................................................................................................................10
Entering address via dip switches, an example ....................................................................................14
Recommended wiring diagram for one MCD device.............................................................................16
Wiring diagram for a number of MCD devices connected to a single gateway.....................................16
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1
INTRODUCTION
1.1 Important user information
This manual describes operation and programming of a
PROFIBUS Gateway for MCD3000 Soft Starters and MCD
Remote Operators, gateway firmware revision 3.0x.
Throughout this manual the term “the gateway” refers to the
MCD - Profibus Gateway, the term ”soft starter” refers to an
MCD3000 Soft Starter and the term “MCD device” refers to
either a soft starter or an MCD Remote Operator that is directly
connected to the gateway.
Gateways with firmware version 3.0x support MCD protocol as
described in Danfoss manuals MG.15.Ax.02 and MG.17.Ex.02. It
is compatible with:
•
•
Soft starters with software version MCDI V6.1 or greater,
MCD Remote Operator Batch #12 or greater.
Contact Fieldbus Specialists if you require a firmware version
that supports earlier models.
Observe all the necessary safety precautions when controlling
any MCD device over the serial communications link, including
alerting personnel that the machinery may start without
warning.
1.2 General
The gateway can be connected to a number of MCD devices
over a single RS-485 cable using a proprietary protocol, specific
to MCD devices. The gateway operates as a single PROFIBUS
slave node. The PROFIBUS master can control all connected
MCD devices – start, stop, reset trip conditions and read
operational status, motor conditions or trip status.
The gateway is a certified PROFIBUS slave device. A number of
gateways and other PROFIBUS slave devices can be
connected to the same network, subject only to standard
PROFIBUS limitations.
The gateway is a master on the RS-485 multi-drop MCD
communications network. Up to 23 MCD devices may be
connected to a single Gateway. In this way up to 23 MCD
devices will share one PROFIBUS address on the PROFIBUS
communications network.
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This manual describes how the gateway operates, how to
connect MCD devices to the gateway and how to connect
and operate the gateway on a PROFIBUS network.
When reading this manual, it may help to refer to the MCD
Soft Starter instructions, Danfoss document no. MG.15.Ax.02
and MCD Remote Operator instructions, Danfoss document
no. MG.17.Ex.02.
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2
INSTALING THE GATEWAY
2.1 Gateway connection diagram
The diagram below shows how the gateway is connected to
the PROFIBUS network and to the RS-485 sub-network.
PROFIBUS DP
Master
PROFIBUS network
MCD3000 - Profibus
Gateway
DP Slave
DP Slave
RS-485 sub-network
MCD
device
MCD
device
MCD
device
MCD
device
Figure 1. Typical diagram of a PROFIBUS network, a gateway
and an RS-485 sub-network.
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2.2 Front panel
4
6
MCD 3000 - PROFIBUS Gateway
FS-1135
RS485
STATUS
5
ADDRESS
1 2 3 4 5 6 7 8
ON
POWER
LSB
RS485
1
3
PROFIBUS
STATUS
+ _
24V DC
PROFIBUS
2
Figure 2. Gateway front panel
Fig. 2 shows the front panel of the gateway. Located on the
front panel are:
1. RS-485 sub-network connector for connecting MCD
devices, DB9, male,
2. PROFIBUS network connector, DB9, female,
3. Power connector, 2 pin removable terminal block,
4. Bi-colour PROFIBUS status LED,
5. Bi-colour RS-485 status LED,
6. Dip switches for PROFIBUS address selection.
The following table indicates the status of the PROFIBUS
connection.
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PROFIBUS
LED
RS-485
LED
Gateway status
Gateway starting (max. 6 sec) or no power
B
B
R/B
ANY
Invalid PROFIBUS address
R/B
ANY
PROFIBUS link down – no PROFIBUS master,
incorrect address or no connection,
G/R/B
ANY
PROFIBUS link error – wrong configuration or
parameters in PROFIBUS master
G
ANY
PROFIBUS link up and problem-free
G
R/B
No communication on the RS-485 link
G
G/R
Occasional errors on the RS-485 link
G
G
Both PROFIBUS and RS-485 links operational
and error-free
Legend:
B
G
- LED off
- LED steady green
R/B
-
LED flashing red/off
G/R
-
LED flashing green/red
G/R/B
-
LED flashing green/red/off
ANY – applies irrespective of LED status
Table 1 – LED Indication
These simple rules may be worth remembering:
-
MCD - PROFIBUS Gateway
Flashing indicates errors on the relevant link,
Flashing red means that the gateway attempts to
communicate but fails every time,
Flashing red/green means that the gateway can
communicate, but errors occur.
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2.3 Installation sequence
When installing the gateway, we recommend the following
sequence:
Connect power, see section 2.4 for details. If there are no
indications of power, check voltage and polarity.
Set the PROFIBUS address on dip switches, configure and
activate PROFIBUS master, see section 2.5 for instructions.
Configure the PROFIBUS master for one MCD device only.
On success the PROFIBUS status LED will go green, on error
it will blink red. If the LED stays red, check the cable,
address on the gateway and address setting in the
master. If the LED flashes green/red, verify the
configuration of modules in the PROFIBUS master. Do not
proceed further unless the PROFIBUS LED is steady green.
Configure and connect the first MCD device, set it to
address 1, see section 2.6 for details. On success, the RS485 status LED should go green. We recommend initially
to configure PROFIBUS master for only one MCD device
connected to the gateway and to get this configuration
working successfully. Later on you can increase the
number of MCD devices. If the RS-485 status LED stays
solid red, check the RS-485 cable, configuration of the
MCD device, wiring and the value of the PROFIBUS
parameter in the gateway configuration data in PROFIBUS
master – RS-485 sub-network baud rate setting.
Configure and connect the remaining MCD devices,
make also the relevant changes to the configuration of
PROFIBUS master. On success the RS-485 LED should go
solid green. If it flashes green/red, one or more MCD
devices do not communicate with the gateway.
2.4 Power connection
The gateway requires 24V DC power, approx. 130mA. The
voltage can be unregulated – the gateway will operate
correctly for power voltage in the range 12-32V. The current
drawn changes with voltage –~240mA for 12V and ~90mA for
32V. The power connector is a removable terminal block,
2 pin. The device is reverse polarity protected – in the case of
reversed connection it will not get damaged but it will not
operate either.
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Presence of correct power can be verified by looking at the
LEDs on the front panel – at least one LED should be illuminated
at all times, whether green or red.
2.5 PROFIBUS connection
The PROFIBUS socket of the gateway must be connected to a
PROFIBUS network in accordance with PROFIBUS Technical
Guideline “Installation Guideline for PROFIBUS DP/FMS”,
PROFIBUS International Order No. 2.112.
2.5.1
Cabling
The gateway PROFIBUS connection requires a PROFIBUS cable
with DB9 male connector. Pin assignment in the PROFIBUS
socket is as follows:
DB9 socket Pin
Purpose
1
Shield/functional ground
2
Not connected
3
RXD/TXD-P (Data Line)
4
Not connected
5
Data ground (reference potential for VP)
6
VP – supply voltage, +5V
7
Not connected
8
RXD/TXD-N (Data Line, Inverted)
9
Not connected
Table 2 – PROFIBUS socket pin assignment
Pins 3 (RXD/TXD-P) and 8 (RXD/TXD-N) must be connected. The
other pins can be used, if needed.
The gateway does not provide termination on the PROFIBUS
cable. If the gateway is located at either end of the cable,
the termination resistors should be provided externally, usually
in a PROFIBUS plug with the termination option. The gateway
provides termination power on pins 5 and 6, in accordance
with the PROFIBUS Specification.
The shield on the PROFIBUS socket is galvanically connected to
the metal top lid on the enclosure. An earthing lug is provided
for earthing the top lid. When the PROFIBUS cable plug is in the
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socket, the shield on the PROFIBUS cable is connected with the
socket shield, the top lid and the earthing lug.
2.5.2
Gateway configuration
The gateway automatically detects the baud rate for the
PROFIBUS network. All standard baud rates are supported as
per PROFIBUS Specification, up to 12 Mbits/s.
The PROFIBUS node address of the gateway is configured with
an 8-way DIP switch that is located on the front panel of the
gateway. The address must be set to a value that is not in use
by any other device on the PROFIBUS network. Valid address
range – 0 to 125.
The procedure for setting the node address of the gateway is
as follows:
Ensure that the device is not powered up by unplugging
the power connector.
Set the DIP switches to the desired value (see figure
below).
Reinsert the power connector
Fig. 2 shows the location of the DIP switches on the front panel.
These switches are used to enter the address, with the most
significant bit on the left and the least significant bit on the
right. The address is entered in binary, with the switch in up
position for ‘0’ and in the switch in the down position for ‘1’.
For example, to set the address “3”, binary 0000 0011, the
switches need to be positioned as follows.
ADDRESS
1 2 3 4 5 6 7 8
ON
LSB
Figure 3. Entering address via dip switches, an example
In addition to setting the address, it is necessary to define the
gateway’s configuration in the PROFIBUS master. For detailed
description of this important stage, refer to section 3.
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2.6 MCD connection
2.6.1
Cabling
The MCD devices should be connected to the RS-485 serial
sub-network as per the relevant Operating Instructions. The
gateway is connected to the RS-485 sub-network using a 9 pin
male DB connector, located to the left side of the enclosure.
Pin assignment is as the following table indicates.
Pins not listed there are unused or reserved and MUST NOT be
connected.
Pin Number
Purpose
1
+ Signal
5
Shield/Ground
9
- Signal
Table 3 – RS-485 pin assignment
We recommend using a shielded twisted pair cable. When the
gateway is located away from the MCD device, the
communications cable should be shielded and should not be
run in the vicinity of high current power cabling. It is advisable
to fit termination resistors at each end of the cable to match its
characteristic impedance, typically in the range of 100-120
ohm.
The recommended connection diagrams are shown in fig. 4
and fig. 5 below. We recommend connecting cable shield on
the gateway side only and we recommend that the
connection point 61 or B7 on the MCD device be left
unconnected.
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SERIAL COMM.
PORT RS485
68 or B8
+
to pin 1
to pin 5
to pin 9
61 or B7
GND
RS485
69 or B6
_
cable shield
MCD device
MCD - PROFIBUS
Gateway
Figure 4. Recommended wiring diagram for one MCD device.
68
Soft
starter
+
61
GND
69
_
B8
B3
+
MCD
B2
Remote
+
B7
GND Operator GND
B6
B1
_
_
68
Soft
starter
+
61
GND
69
_
68
Soft
starter
+
61
GND
69
_
to pin 1
to pin 5
to pin 9
MCD3000 Profibus
gateway
Figure 5. Wiring diagram for a number of MCD devices
connected to a single gateway
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If a number of MCD devices are connected to a single
gateway, we recommend wiring them as in fig. 5. The cable
should constitute a single line, without side branches.
Note that we recommend connecting GND points (61 or B7)
on all MCD devices to guarantee that they share the same
ground potential. If the devices are connected to the
common ground in some other way (ex. via a metallic
mounting), it may not be necessary to connect points 61 or B7.
RS-485 interface on MCD devices is not galvanically isolated.
Failure to equalize ground potential on all MCD devices
connected via RS-485 link may result in their damage.
2.6.2
MCD device configuration
The gateway can communicate at any of the baud rates that
MCD devices can support. All MCD devices connected to the
same sub-network must be configured for the same baud rate.
Each MCD device must be configured with a node address.
Each must have a different address and each address must be
in the range 1 to the number of MCD devices connected to
the gateway, inclusive. Example: if four devices are
connected to a gateway, they must have addresses 1, 2, 3
and 4.
For MCD Remote Operators connected to the gateway, the
term “address” refers to the MCD Remote Operator address,
Parameter 2, not the address of the soft starter connected to
the MCD Remote Operator.
For soft starters connected directly to the gateway,
Local/Remote Mode parameter (Parameter 20) must be set to
0, 1 or 2. Setting this parameter to 3 disables the RS-485
communications port. For more detailed explanation refer to
the MCD3000 Soft Starter Operating Instructions.
Soft starter must be set for “Local” operation using the
Local/Remote pushbutton on the front panel. When this is
done, the LED labeled “REMOTE” on the front panel is off.
NOTE: When the soft starter is set for “Remote”, it does not
execute commands received over the RS-485 link. However, it
still acknowledges these commands. Consequently, the
gateway and the PROFIBUS master cannot detect this
condition. For working with a gateway, we recommend to set
Local/Remote Mode parameter (Parameter 20) to 2 – “Local
control only”. This will eliminate the possibility of the Soft Starter
being accidentally set for “Remote”.
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The MCD devices must be configured using the keypad/LCD
display on their front panels. The method of setting parameters
is described in details in the Operating Instructions.
The following tables show the relevant parameters for a soft
starter connected directly to the gateway.
Parameter 20
Local/Remote Mode
Configuration Options
0-3
Acceptable settings
0-2
Recommended setting
2
Unacceptable setting
3
Table 4 – Soft starter Local/Remote modes
Parameter 22
Serial communication baud rate
Configuration Options
1 -5
Acceptable settings
1-5
Default Setting
4 – 9600 baud
Table 5 – Soft starter RS-485 baud rate values
Parameter 23
Address for RS-485 serial
communications
Configuration Options
1 – 99
Required Setting
A number between 1 and the total
number of MCD devices on the
network
Table 6 – Soft starter address on RS-485 network
For soft starters connected to the gateway via a Remote
Operator, refer to the Remote Operator instructions for soft
starter configuration. The following tables show the relevant
parameters for an MCD Remote Operator connected directly
to a gateway.
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Parameter 1
Serial communication baud rate
Configuration Options
1 -5
Acceptable settings
1-5
Default Setting
4 – 9600 baud
Table 7 – MCD Remote Operator RS-485 baud rate values
Parameter 2
Address for RS-485 serial
communications
Configuration Options
1 – 99
Required Setting
A number between 1 and the total
number of MCD devices on the
network
Table 8 – MCD Remote Operator address on RS-485 network
Parameter 4
RS485 Network Protocol
Configuration Options
1,2
Required settings
1
Table 9 – MCD Remote Operator network protocol
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3
PROGRAMMING THE MASTER CONTROLLER
3.1 GSD file
Information on the technical characteristics of the gateway is
loaded into PROFIBUS master software by means of a GSD file.
A floppy disk with the GSD file is supplied with the gateway.
The GSD file name is “FS1135.GSD”. Follow the instructions in
the PROFIBUS configuration/management software manual for
loading the GSD file and adding a new node to the network.
If you need a copy of the GSD file, please contact us at
[email protected]
For the PROFIBUS master to communicate with the gateway, it
must be provided with information about the way that the
gateway works. You can do it by following these steps:
load the GSD file, for details refer to the manual for
master configuration software,
declare the required modules within the gateway,
if default parameters are not suitable, change these
parameters.
3.2 Declaring modules
The gateway is a modular PROFIBUS slave, consisting of several
modules as defined in the GSD file. The GSD file defines two
types of modules – a Control Module and an MCD device
module.
The Control Module has 10 bytes of input data and 3 bytes of
output data, no consistency. It must be declared as the first
module in the configuration.
If you cannot establish communication with PROFIBUS master,
verify that the configuration of the gateway in the master. If
the first module is not as above – 10 bytes IN and 3 bytes OUT,
redefine the gateway configuration.
In addition to the Control Module, you must declare an MCD
device module (5 Bytes In, module with data consistency) for
each MCD device connected to the gateway. The gateway
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assumes that the addresses of the MCD devices start at 1 and
are consecutive, up to the number of expected devices.
The first MCD device module relates to the MCD device with
address 1, the second one to 2 and so on. Address values are
not related to physical positioning of MCD devices on the RS485 sub-network.
NOTE for users of SIMATIC S7:
Slave modules are defined as so called “modules with data
consistency”. This is necessary to guarantee accuracy of
reading the current. The consequence of it in S7 is that module
data cannot be read directly – direct reading always returns 0.
Instead, you should use SFC14 to cyclically copy module data
to PLC internal memory and then retrieve the required values.
In case of problems consult an S7 expert re. the memory
addresses to be used for slave modules and the correct way of
retrieving module data.
3.3 Setting PROFIBUS parameters
The gateway requires three parameters, associated with the
control module in the gateway configuration. The first
parameter defines the desired baud rate on the RS-485
network. The gateway supports all the baud rates that the
MCD devices support:
First Parameter
Value
Baud Rate
1
1,200 bps
2
2,400 bps
3
4
4,800 bps
9,600 bps (Default)
5
19,200 bps
Table 10 – Gateway parameter, RS-485 link baud rate
The second parameter defines gateway operation if
communication with the master stops:
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Second
parameter
Action on communication
breakdown
1
2
Stop polling MCD devices
STOP command sent to all
MCD devices
3
COAST TO STOP sent to all
devices
Table 11 – Gateway parameter, gateway operation on
communication loss
The selected action will be executed when the gateway had
established initial communication with the master and
subsequently this communication stops.
If the second parameter is set to 1, the gateway will stop
poling MCD devices on communications breakdown. This may
cause soft starters to trip, if they are so programmed
(Parameter 24). For other values of the second parameter, the
gateway will keep on polling and will prevent soft starters from
tripping.
The third parameter defines the timeout, in seconds, for
communication with the master.
If the gateway stays off-line on PROFIBUS for the time period as
set in the third parameter, the gateway will take action as
defined by the second parameter. Allowed range is 0 to 255.
Default value is 5, setting the timeout at 5 sec. If the third
parameter is set to 0, no timeout supervision will be carried out
and once communication with master commences, the
gateway will keep on polling MCD devices irrespective of the
status of gateway-master link.
On receiving an invalid parameter value or invalid
configuration data from the PROFIBUS master, the gateway
goes offline and flashes the PROFIBUS status LED green, red and
then turns it off. After a few seconds the PROFIBUS master will
try again to set the gateway to ONLINE state and the cycle
repeats until the error is corrected.
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3.4 Master-slave data exchange
Data exchanged between PROFIBUS master and slaves are of
two types – configuration data and process data.
Configuration data are transmitted once only when the master
establishes communication with the slave. These data carry
information about slave configuration – the modules declared
there. Also included in the configuration data are parameters,
sent from master to the slave. In case of the gateway, the
configuration data instruct the gateway about the number of
MCD devices to scan, about the baud rate on the RS-485
network and about required action if the gateway goes offline on PROFIBUS.
Process data are the data transmitted cyclically between the
master and slave. The PLC writes the data for the slave to the
Write area and reads the data from the slave from the Read
area. Locations of the Write and Read areas in the PLC
memory are specific to each PLC. For details consult the PLC
manual.
3.5
Data write area
The only write data (data transferred from PROFIBUS master to
the gateway) are contained in the control module – 3 bytes of
data. These three bytes are used to issue commands to MCD
devices, as described later in this manual.
The first byte is the Master Handshake Register. Only the two
least significant bits B0 and B1 are used, the other six bits are
ignored by the gateway. Meaning of the value of bits B0 and
B1 is explained later in this document.
The second byte is the Command Register. When PROFIBUS
master controller issues a command to a MCD device, it writes
the code of the command to the Command Register. Table
15 below shows all the valid values – command codes - that
can be written to the Command Register and the commands
associated with these values. The values in the table are
shown in hexadecimal. These values have been chosen to
resemble the original command codes as used by MCD
devices. For example, the ASCII command code for Stop is
“B12”. The hexadecimal value selected for Stop is B2 (hex),
0xB2 in C language notation and 1011 0010 in binary.
The third byte – Address Register – contains the RS-485 subnetwork address of the MCD device that the command is for.
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Offset
Contents
Comments
0
Master
Handshake
Register
Bit B0: New Command Bit.
Bit B1: Result Acknowledge Bit.
1
Command
Register
see Table 15 below
2
Slave Address
Register
Address of the slave that the
command is for.
Table 12 – PROFIBUS Write / Out Memory
3.6 Data read area
Read data (data that the PROFIBUS master reads from the
gateway) come from the control module – 10 bytes – and from
each slave module defined for MCD devices – 5 bytes for
each MCD device. Actual memory addresses depend on
programming of the master controller, so in the following
description we refer to offsets, where the very first byte in a
module is assumed to have offset 0 and the subsequent bytes
within the module follow.
The first byte in the control module – offset 0, Slave Handshake
Register – operates in the way similar to the Master Handshake
Register. Only the bits B0 and B1 are used. More detailed
explanation can be found later in this document.
The second byte at offset 1 carries the code of the outcome of
the command – 1 for success, error codes 2, 3 or 4 in case of
failure, see the table below for details.
Result code
1
2
3
4
Description
Successful completion
The gateway rejected the command – invalid
command code or data
No reply from the target or target rejecting the
command
Invalid target address
Table 13 – Command result codes
The next four bytes (at offsets 2 to 5) carry information about
network status of devices on the RS-485 sub-network. The first
byte (at offset 2) relates to addresses 1-8, the second to 9-16,
the third to 17-23 and the fourth is unused. Four bytes are
always reserved, irrespective of the number of slaves present.
When bit B0 in byte at offset 2 is set, it indicates that the MCD
device with address 1 is present and communicating. Similarly,
bit B1 set indicates slave 2 present. A bit set to 0 means that
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the corresponding slave is not present or not communicating.
Bits related to slaves not declared on the network are always
set to 0.
All data related to a slave (status data, trip codes, current and
temperature) are valid only if the relevant network status bit is
set.
The four bytes at offsets 6-9 are used for commands that return
data, such as Request Status. The content of these bytes is the
same as the content of the data part of a reply received from
the MCD devices, refer to the relevant MCD device Operating
Instructions for more details.
Slave modules have 5 read bytes each, one block for each
MCD device. The structure of each 5-byte block is the same,
see Table 14. This table assumes consecutive placement of
modules in master’s memory. If your master controller places
modules differently, the offset values will be different.
The value in two-byte Current register is an unsigned 16-bit (two
byte) integer in the range 0-9999, with the first byte being the
least significant one and the second byte being the most
significant.
The last byte – Temperature register - carries information about
motor’s temperature, given as percentage of the motor’s
thermal capacity, range 0 to 250%, encoded as an unsigned
integer. If the MCD device reports motor temperature greater
than 250%, the gateway will report 250%.
As a general rule, all unused bits or bytes are always set to 0.
Table 14 shows the structure of the Read area for a controller
that allocates modules consecutively in memory. For other
controllers, such as S7, the values of offset start from 0 for each
module and placement of consecutive modules in PLC
memory can be arbitrary.
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Offset
10-byte
control block
5-byte block
for address 1
Contents
Comments
0
Slave Handshake
Register
Bit B0: Command Ackn. bit
Bit B1: Result Ready bit
1
Command Result
Register
1: Success.
2: Invalid/rejected command.
3: No/rejected response from
slave.
4: Invalid slave address
2
Online Slaves Register 1
Bit B0: Slave 1 online.
…
Bit B7: Slave 8 online.
3
Online Slaves Register 2
Slave 9 online - Slave 16 online.
4
Online Slaves Register 3
Slave 17 online - Slave 23 online.
5
Online Slaves Register 4
unused
6-9
Data Read Registers
Command Data Reply
10
Status for address 1
Status value for device at address 1
11
Trip for address 1
Trip value for device at address 1
Current for address 1
Motor Current, 0 – 9999 Amps.
12-13
5-byte block
for address 2
14
Temperature for addr. 1
Motor Thermal Capacity, 0 – 250%
15
Status for address 2
As above
16
Trip for address 2
As above
Current for address 2
As above
19
Temperature for addr. 2
As above
…
…
…
…
…
…
17-18
5-byte block
120
Status for address 23
As above
for address
23
121
Trip for address 23
As above
122123
Current for address 23
As above
124
Temperature for addr.
23
As above
Table 14 – PROFIBUS Read / In memory
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3.7 Issuing Commands
PROFIBUS master can issue commands to each MCD device at
any time. The following Table 15 lists the commands as well as
the purpose of these commands. The commands are shown in
hexadecimal notation.
Command
Action
0xB0
Start Motor
0xB2
Stop Motor
0xB4
Reset Trip State
0xB6
Coast To Stop
0xC2
Read Status
0xC6
Read RS-485 Protocol Version
0xC8
Read Trip Status
0xD0
Read motor Current
0xD2
Read Motor Temperature
0xFF
Read Gateway Firmware
Revision
Table 15 – Valid commands
This is the procedure for issuing a command:
Write the slave address into the Slave Address Register
(Control module, Write data, byte at offset 2),
Write the command into the Command Register (Control
module, Write data, byte at offset 1),
As the last step, toggle the Command Request Bit in the
Master Handshake Register (Control module, Write data,
byte at offset 0) - change the bit from 0 to 1 or from 1 to 0
- so that it is different from the Command
Acknowledgment Bit in Slave Handshake Register.
Then the following happens:
The gateway toggles the Command Acknowledge Bit in
Slave Handshake Register (Control module, Read data,
byte at offset 0) to make it the same as the Command
Request Bit. This indicates an acknowledgement of the
command (but not its completion).
When the command processing has finished, whether
successfully or not, the gateway places the results into the
Command Result Register (Control module, Read data,
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byte at offset 1).
In the last step the gateway toggles the Result Ready Bit in
Slave Handshake Register (Control module, Read data,
byte at offset 0), indicating the completion of the
command as well as the availability of the results.
This is how Master can read the outcome of the command:
Upon detecting change of value of the Result Ready Bit,
PROFIBUS master should read the Command Result
Register (Control module, Read data, byte at offset 1).
If the command was “Read Status” or “Read Trip Status”,
PROFIBUS master can also read the Data Read Registers.
These are bytes at offsets 6 through to 9 in the Control
module Read data. The content of these four bytes is the
same as the four bytes that MCD device sends in reply to
the equivalent command, refer to the MCD device
Operating Instructions for details.
If the command was “Read Gateway Firmware Revision”,
PROFIBUS master can retrieve the content of the Data
Read Registers, bytes at offsets 6-9 in Control Module. The
firmware revision is encoded as four ASCII characters.
Example – for Rev. 3.01, the content of the four data bytes
will be ‘0’ (0x30), ‘3’ (0x33), ‘0’ (0x30) and ‘1’ (0x31).
As the last step, PROFIBUS master should toggle the
Command Acknowledge Bit in the Master Handshake
Register (Control module, Write data, byte at offset 0) to
indicate to the gateway that the result/reply has been
read.
PROFIBUS master must NOT issue a command until:
-
the gateway has acknowledged the previous command –
bits B0 in Master and Slave Handshake Registers are equal,
whether 0 or 1,
-
the reply to it has been acknowledged – bits B1 in Master
and Slave Handshake Registers are equal, whether 0 or 1.
Status of the motor can be affected by a number of factors
other than commands. Consequently, you must not assume
that the motor is in any particular state even if a command has
been accepted and returned Success in Command Result
Register. To monitor status of the motor, the master controller
should continuously monitor the Status register.
An attempt to issue a command before the gateway has
acknowledged and responded to the previous one will be
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ignored and may lead to an unpredictable behaviour of the
gateway.
On startup, the PROFIBUS master should set the Master
Handshake Register to 0. The gateway resets Slave Handshake
Register to 0 while not on PROFIBUS network. This guarantees
proper startup conditions for the handshaking mechanism. We
recommend that PROFIBUS master program checks the correct
startup conditions – bits B0 and B1 in both handshake registers
being equal.
The tables below show possible combinations of handshaking
bits and their meaning. Symbol X means either 0 or 1, /X
means the opposite to X.
New
Command
Bit (B0)
Command
Acknowledge
Bit (B0)
Meaning
X
/X
Bits are different. PROFIBUS master
has issued a command, but the
gateway has not accepted it yet.
X
X
Bits are the same. No command or
the gateway has accepted the
command.
Table 16 – New Command / Command Acknowledge
handshaking
Result Ready
Bit (B1)
Result
Acknowledge
Bit (B1)
Meaning
X
/X
Bits are different. The gateway
placed command results in
PROFIBUS data and awaits the
master’s confirmation.
X
X
Bits are the same. No results or the
result has been read.
Table 17 – Result Ready / Result Acknowledge handshaking
It is the gateway’s responsibility to acknowledge the
command bits via the ‘Command Acknowledge Bit’. It is the
PROFIBUS master’s responsibility to acknowledge the result bits
via the ‘Result Acknowledge Bit’. Failure to follow the
handshaking procedure may lead to unpredictable behaviour
of the gateway.
Commands take precedence over scanning of slaves and will
be executed within 250 msec. If the PROFIBUS master detects
undue delay in gateway acknowledging the command or
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sending a response, it should restart the gateway by placing it
in OFFLINE state and then returning it to ONLINE.
This is an example of the complete procedure for resetting trip
state of an MCD device at address 3 using Reset Trip State
command:
1. Check that the device is on-line, i.e. the network status bit
is set – in this case check Read byte at offset 2, bit B2. If this
bit is set to 1, you can proceed. If the bit equals 0, the
device at address 3 is offline.
2. Check that previous commands have been completed –
Master Handshake Register and Slave Handshake Register
are equal.
3. Write command code 0xB4 (Reset Trip State) to Command
Register - byte at offset 1 in Write area. Also write slave
address 3 to Address Register – byte at offset 2 in Write
area. The sequence in which these bytes are being written
into is irrelevant.
4. Modify bit B0 in Master Handshake Register – change it
from 0 to 1 or from 1 to 0, whichever is applicable, to
indicate to the gateway that a command is pending. You
may monitor that bit B0 in Slave Handshake Register
changes to equal bit B0 in Master Handshake Register,
indicating that the gateway device accepted the
command. Be aware that this change does not have to
be immediate.
5. Wait for bit B1 in Slave Handshake Register to change,
indicating that a reply is waiting. This may take some time,
needed for execution of the command.
6. Read Command Result Register. If it equals 1, the
command has been successful. If Command Result
Register equals 2, 3 or 4, the command failed. In either
case, acknowledge the response by modifying bit B1 in
Master Handshake Register to make it equal B1 in Slave
Handshake Register.
For commands that do not return any data (such as Start or
Stop), there is no need to read Data Read Registers at offsets 6
to 9.
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4
OPERATION OF THE GATEWAY
4.1 Scanning slaves
The gateway starts scanning slaves only after the PROFIBUS
master sends the configuration data and the gateway goes
online on PROFIBUS.
The gateway periodically retrieves Status, Trip Code, Current
and Temperature from each slave and updates the PROFIBUS
process Read data in an autonomous fashion. Status and Trip
Code are being read most frequently – in each scan cycle,
Current is read once every third scan cycle and Temperature
every tenth scan cycle.
On the first scan the Status, Trip Code, Current and
Temperature are read from all declared devices. The device
network status bits in the Read area, offset 2-4, are set for all
slaves that reply, refer to Table 14.
If an MCD device fails to respond to a data request command,
it is considered an “Offline Slave” and has it’s corresponding
network status bit cleared. Also cleared are the process data
bytes related to this device.
Note that Status, Trip code, Current and Temperature process
data for each slave in PROFIBUS master memory are valid only
if the relevant network status bit is set. If the network status bit
is not set, then the process data associated with that particular
slave are invalid.
4.2 Scanning times
The following Table 18 gives an indication of the time required
to complete a polling cycle for a number of slaves present on
a serial link over the supported baud rates. The times are in
seconds. These figures indicate possible delay in detecting
changes to Status and Trip code – data read in each scan
cycle.
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No. of
Devices
1,200
bps
2,400 bps
4,800 bps
9,600 bps
19,200
bps
1
0.500
0.300
0.190
0.130
0.110
2
1.000
0.600
0.380
0.260
0.220
3
1.500
0.900
0.570
0.390
0.330
4
2.000
1.200
0.760
0.520
0.440
5
2.500
1.500
0.950
0.650
0.550
10
5.000
3.000
1.900
1.300
1.100
15
7.500
4.500
2.850
1.820
1.650
20
10.000
6.000
3.800
2.600
2.200
Table 18 – Scanning cycle length for different baud rates and
the number of MCD devices present
The Current register is scanned once every three scan cycles.
Consequently, the average time between two consecutive
reads of the current register of the MCD devices is three times
greater than the time as in the table above.
The Temperature register is scanned once every ten scan
cycles. Consequently, the average time between two
consecutive reads of the Temperature register of the MCD
devices is ten times greater than the time as in the table
above.
The gateway will automatically detect if a MCD device that
was declared offline becomes available again. The Table 19
shows the worst case time for detecting such a device,
assuming that only one device on the network is offline. The
time is in seconds.
No. of
Devices
1,200
bps
2,400
bps
4,800
bps
9,600
bps
19,200
bps
1
0.250*
0.250*
0.250*
0.250*
0.250*
2
5.000
3.000
1.900
1.300
1.100
3
7.500
4.500
2.850
1.950
1.650
4
10.000
6.000
3.800
2.600
2.200
5
12.500
7.500
4.750
3.250
2.750
10
25.000
15.000
9.500
6.500
5.500
15
37.500
22.500
14.250
9.750
8.250
20
50.000
30.000
19.000
13.000
11.000
* Only the offline device is on the network, so no other
scanning takes place.
Table 19 – Maximum time to detect return of an offline device
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4.3 Offline slaves
Since up to 23 slaves can share the same RS-485 serial link, it is
critical that communication delays are kept to a minimum.
Slaves that are slow to respond slow down the entire serial link.
It is important that slaves that fail to respond do not hold up
the gateway. The following scheme is used to handle offline
slaves:
If a slave fails to respond to a command, it is considered
an offline slave and joins a list of offline slaves, internal to
the gateway.
In each polling cycle all online slaves are polled. After 5
polling cycles, a command is sent to one of the offline
slaves.
On a subsequent offline slave poll, the next slave on the
list of offline slaves is polled.
Once an offline slave responds to a command it is no
longer considered an offline slave.
This mechanism helps keep network delays to a minimum while
also being able to recover offline slaves when they come
online.
The above mechanism allows connecting/disconnecting MCD
devices while the network is working, with minimal impact on
the rest of the network.
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5
SPECIFICATIONS
Item
Value
Enclosure
- Width
100 mm
- Height
75 mm
- Depth
110 mm
Mounting
DIN Rail or Screw
Mounting
PROFIBUS Interface
- Connector Type
9 Pin DB Female
- Galvanically Isolated
Yes (850V)
- Status Indicator (Type)
5mm Bi-Coloured LED
- Configured
Dip switches (Address)
MCD Subnetwork Interface
- Connector Type
9 Pin DB Male
- Galvanically Isolated
Yes (1000V)
- Status Indicator (Type)
5mm Bi-Coloured LED
- Configured
Via PROFIBUS
Power
- Voltage
24V
- Consumption
3.2 Watts
- Connector Type
Removable Screw
Terminal
- Reverse Polarity Protection
Yes
- Surge / Short Protection
Fuse
Other Items
- Field Programmable
Yes
- Weight
Approx. 350g
- Protection Class
IP 20
Table 20 – Gateway specifications
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6
TROUBLESHOOTING
Indications
Problem
Possible cause (check in the order listed)
LEDs all off for
extended period
No power
No power
Incorrect polarity
Gateway’s fuse blown
Both LEDs flashing red
PROFIBUS address
invalid
PROFIBUS address on DIP switches set
outside the valid range 0-125
PROFIBUS Status LEDs
flashing red,
No communication
with PROFIBUS master
PROFIBUS master is disconnected or off
PROFIBUS cable is cut/broken/not installed
correctly
PROFIBUS address set incorrectly
High inducted noise on the cable
PROFIBUS Status LEDs
flashing
green/red/off
Gateway
communicating with
PROFIBUS master, but
unable to establish
data link
Incorrect gateway configuration
information in PROFIBUS master, incorrect
parameter value
RS-485 Status LED
flashing red
No communication on
RS-485 link
RS-485 cable fault (cut/broken/not installed
correctly)
No devices are configured correctly for
operation over RS-485
No device addresses are set correctly
RS-485 Status LED
flashes red/green
Errors on RS-485 link,
but some
communication still
takes place
Some devices not present
Some devices are not configured for remote
operation over RS-485
Some device addresses are set incorrectly
Incorrect gateway configuration
information in PROFIBUS master
PROFIBUS master issues invalid
command/request
Table 21 – Troubleshooting guide
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