MCD 3000 Series Soft Starters to PROFIBUS
Contents
1. Connector Type Removable Screw Terminal Reverse Polarity Protection Yes Surge Short Protection Fuse Other Items Field Programmable Weight Protection Class IP 20 Table 17 Gateway specifications MCD 3000 SERIES 32 USER MANUAL MCD 3000 PROFIBUS GATEWAY 6 TROUBLESHOOTING Indications Problem Possible cause check in the order listed LEDs all off for No power No power extended period Incorrect polarity Gateway s fuse blown Both LEDs flashing red PROFIBUS address PROFIBUS address on DIP switches set invalid outside the valid range 0 125 PROFIBUS Status LEDs No communication PROFIBUS Master is disconnected or off flashing red with PROFIBUS Master PROFIBUS cable is cut broken not installed correctly PROFIBUS address set inc orrectly High inducted noise on the cable PROFIBUS Status LEDs Gateway Incorrect gateway configuration flashing communicating with information in PROFIBUS Master incorect green red off PROFIBUS Master but parameter value unable to establish data link RS 485 Status LED No communication on RS 485 cable fault c ut broken not installed flashing red RS 485 link correctly No devicesare configured correctly for operation over RS 485 No device addresses are set correctly RS 485 Status LED Errors on RS 485 link Some devices not present flashes red green but some Some devices are not configured for remote communication still operation over RS 485 takes2. refer to section 3 MCD 3000 SERIES 13 USER MANUAL MCD 3000 PROFIBUS GATEWAY 2 6 MCD3000 connection 2 6 1 Cabling The MCD 3000 devices should be connected to the RS 485 serial sub network as perthe MCD 3000 Operating Instructions The gateway isconnected 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 orreserved and MUSTNOTbe connected Pin Number Purpose Shield Ground 9 Signal Table 3 RS 485 pin assignment We recommend using a shielded twisted paircable When the gateway islocated away form the soft starter the communications cable should be shielded and should not be run in the vicinity of high current power cabling It is advisa ble to fit termination resistors at each end of the cable to match its charactenstic impedance typically in the range of 100 120 ohm The recommended connection diagram is shown in fig 4 below We recommend connecting cable shield on the gateway side only and we recommend that the connection point 61 on the MCD3000 device be left unconnected MCD 3000 SERIES 14 USER MANUAL MCD 3000 PROFIBUS GATEWAY 68 0 0 H SE ze LUC expo a RS485 z ka to pin 9 xe DN 69 4 cable shield MCD3000 device Gateway Figure 4 Recommended wiring diagram for one MCD3000 device to pin1 E FS 1135 t
3. MCD 3000 device MCD 3000 device MCD 3000 device Figure 1 Typical diagram of a PROFIBUS network a gateway and an RS 485 sub network A gateway can coexist with a number of other PROFIBUS nodes including othergateways Each gateway constitutes a single PROFIBUS node even if it connectsto a numberof MCD 3000 devices MCD 3000 SERIES 8 USER MANUAL MCD 3000 PROFIBUS GATEWAY 2 2 Frontpanel E fieldbus LA specialists FS 1135 a ADDRESS PROFIBUS 2 3 STATUS STATUS 7 Gei TT Eeer SB O mg o o 24V DC O i RS485 2 PROFIBUS GI Figure 2 Gateway front panel Fig 2 showsthe front panel of the gateway Located on the front panel are 1 RS 485 sub network connector forconnecting up to 30 MCD 3000 devices DB9 male 2 PROFIBUS network connector DB9 female 3 Powerconnector 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 indicatesthe status of the PROFIBUS connection MCD 3000 SERIES 9 USER MANUAL MCD 3000 PROFIBUS GATEWAY PROABUS RS 485 Gateway status B BY Gateway starting max 6 sec orno power RB ANY Invalid PROFIBUS address URB ANY PROFIBUS link down no PROFIBUS Master incomect address or no connection PROFIBUS link error wrong configuration or parameter in Master lg ANY PROFIBUS link up and problem free ANY RB No commun
4. Write area The sequence in which these bytes are being written into is irelevant 4 Modify bit BO in Master Handshake Register change it from Oto 1 or from 1 to 0 whichever is applicable to indicate to the gateway that a command ispending You may monitor that bit BO in Slave Handshake Register changesto equal bit BO in Master Handshake Register indicating that the gateway device accepted the command Be aware that this change doesnot have to be immediate 5 Wait for bit Bl in Save Handshake Registerto change indicating that a reply is waiting This ma y take some time needed for execution of the command 6 Read Command Result Register If it equals 1 retrieve the requested device status from Data Read Registers at offsets 6 to 9 If Command Result Register equals 2 3 or 4 processthe enor In eithercase acknowledge the response by modifying bit B1 in Master Handshake Register to make it equal B1 in Save Handshake Register Forcommandsthat do not retum any data such as Start or Stop there isno need to read Data Read Registers at offsets 6 to 9 MCD 3000 SERIES 28 USER MANUAL MCD 3000 PROFIBUS GATEWAY 4 OPERATION OF THE GATEWAY 4 1 Scanning slaves 4 2 Scanning times The gateway starts scanning slaves only afterthe PROFIBUS Master sends the configuration data and the gateway goesonline on PROFIBUS The gateway periodically retrieves Status 1 Trip Code Curent and Temperature from each slave and u
5. otherthan commands Consequently you MUSTNOTassume that the motorisin any particular state even ifa command has been accepted and retumed Success in Command Result Register To monitor status of the motor the master controller should continuously monitor Status register An attempt to issue a command before the gateway has acknowledged and responded to the previous one will be ignored and may lead to an unpredictable behaviour of the gateway On startup the PROFIBUS Master should set the Master Handshake Registerto 0 The gateway resets Slave Handshake Register to O while not on PROFIBUS network This guarantees MCD 3000 SERIES 26 USER MANUAL MCD 3000 PROFIBUS GATEWAY proper startup conditions forthe handshaking mechanism We recommend that PROFIBUS Master program checks the correct startup conditions bits BO and B1 in both handshake registers being equal The tables below show possible combinations of handshaking bitsand their meaning Symbol X means either 0 or 1 X means the opposite to X New Command Meaning Command Acknowledge Bit BO Bit BO Bits are different PROFIBUS Master hasissued a command but the gateway hasnot accepted it yet X X Bits are the same No command or the gateway hasaccepted the command Table 13 New Command Command Acknowledge handshaking Result Ready Result Meaning Bit B1 Bits are different The gateway placed command results in PROFIBUS data and awaits
6. referto the MCD 3000 Senes Soft Starter Operating Instructions for more details Slave modules have 5 read bytes each one block foreach MCD3000 device The structure of each 5 byte block is the same see Table 11 Thistable assumes consecutive placement of modules in ma ters memory If your master controller places modules differently the offset values will be different The value in Status 1 register is read from the MCD3000 device and then inverted to yield positive logic 1 meaning YES TRUE and O meaning NO FALSE The value in Trip registerisasdescribed in the starter manual The value in two byte Current register is an unsigned integer in the range 0 9999 with the first byte being the least significant one and the second byte being the most signific ant The last byte Temperature register ca mes information about motor stempenature given as percentage of the motors thermal capacity range Oto 250 encoded asan unsigned integer If the MCD3000 device reports motor temperature greaterthan 250 the gateway will report 250 Asa general rule all unused bitsorbytesare alwaysset to 0 Table 11 shows the structure of the Read area fora controller that allocates modules consecutively in memory For other controllers such as S7 the values of offset start from 0 foreach module and placement of consecutive modules in PLC memory can be arbitrary MCD 3000 SERIES 23 USER MANUAL 5 byte block for address 1 5 byte bloc
7. scan cycle MCD 3000 SERIES 29 USER MANUAL MCD 3000 PROFIBUS GATEWAY No of et 2 400 bps 4 800 bps 9 600 bps 19 200 Devices bps Pi osc oso os Joro fono 2 1000 osoo osso 0 260 o220 a 2000 1200 Tome 0520 20 10000 Leo 3 800 2600 220 E EE 15 000 9 000 5 700 3 900 3 300 Table 15 Scanning cycle length for different baud rates and the number of MCD 3000 devices present The Current register is scanned once every three scan cycles Consequently the average time between two consecutive readsof the current register of the MCD 3000 devicesis three times greater than the time asin the table above No of Sie e sie Soe 19 200 Devices bps 1 0250 0250 0250 0 250 0250 2 5 000 3000 1900 130 1100 4 10 000 6000 3800 2600 2200 20 sooom _ 30 000 Tan 13000 11000 pezso arso 2870 1620 13150 75 000 45 000 28 500 19 500 16 500 Only the offline device ison the network so no other scanning takes place Table 16 Maximum time to detect retum of an offline device The Temperature register is scanned once every ten scan cycles Consequently the average time between two consecutive readsofthe Temperature registerofthe MCD 3000 devices is ten times greater than the time as in the table above MCD 3000 SERIES 30 USER MANUAL 4 3 Offline slaves MCD 3000 PROFIBUS GATEWAY The gateway will automatically detect i
8. socket shield the top lid and the earthing lug 2 5 2 Gateway configuration The gateway automatically detects the baud rate forthe PROFIBUS network All standard baud ratesare supported as per PROFIBUS Specification up to 12 Mbits s The PROFIBUS node address of the PROFIBUS to MCD 3000 Gateway isconfigured 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 Oto 125 The procedure forsetting the node address of the gateway is as follows Ensure that the device isnot powered up by unplugging the powerconnector Set the DIP switches to the desired value see figure below Reinsert the power connector Fig 1 showsthe 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 addressis entered in binary with the switch in up position for 0 and in the switch in the down position for 1 Forexample to set the address 3 binary 0000 0011 the switches need to be positioned as follows ADDRESS lelelelelelT jz 345678 LSB Figure 3 Entering addressvia dip switches an example In addition to setting the address it isnecessary to define the gateway sconfiguration in the PROFIBUS Master For detailed description of this important stage
9. the master s confirmation X X Bits are the same No results or the result has been read Table 14 Result Rea dy Result Acknowledge handshaking It isthe gatewa y s responsibility to acknowledge the command bits via the Command Acknowledge Bit It isthe 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 Commandstake precedence overscanning of slavesand will be executed within 250 msec If the PROFIBUS master detects undue delay in gateway acknowledging the command or sending a response it should restart the gateway by placing it in OFFLINE state and then retuming it to ONLINE This isan example of the complete procedure for reading status data of an MCD3000 device at address 3 using Read Status command MCD 3000 SERIES 27 USER MANUAL MCD 3000 PROFIBUS GATEWAY 1 Check that the device is on line i e the network status bit is set in thiscase check Read byte at offset 2 bit B2 If this bit isset to 1 you can proceed If the bit equals O the device at address 3 is offline 2 Checkthat previous commands have been completed Master Handshake Register and Slave Handshake Register are equal 3 Write command code OxCO Request Status to Command Register byte at offset 1 in Write area Also write slave address 3 to Address Register byte at offset 2 in
10. 4 For other values of this parameter the gateway will keep on polling and will prevent MCD3000 tripping The third parameter defines the timeout in seconds for communication with the master Ifthe 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 isO to 255 Default value is 5 setting the timeout at 5 sec If the third parameter isset to 0 no timeout supervision will be ca med out and once communication with master commences the gateway will keep on polling MCD3000 devices imespective of the status of gateway master link On receiving an invalid parameter value or invalid configuration data from the PROFIBUS master the gateway goesoffline and flashes the PROFIBUS status LED green red and then tums 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 eroriscorected MCD 3000 SERIES 20 USER MANUAL MCD 3000 PROFIBUS GATEWAY 3 4 Masterslave data exchange 3 5 Data write area Data exchanged between PROFIBUS master and slave are of two types configuration data and processdata Configuration data are transmitted once only when the master esta blishes communication with the slave These data cany information about slave configuration the modules declared there Also included in the configuration data are parameters sent from m
11. AMMING THE MASTER CONTROLLER 0 cccccsesscccssssssesessenseenssesesesueaeasesesesnseaoans 18 SE E EE AR EEA E AA A A er EE ee ee 18 3 2 DECLARING MODULE ES ocococococococonoconocanananananananara rara ra narrar 18 3 3 SETTING PROFIBUS PARAMETERS cccccccccccsssssssssesccscsesseessesseccsessesssssescsesseesssssescsessesesesessesesenseesees 19 34 MASTER SLAVE DATA EXCHANGE EEN EEN 21 IL DATA WRITEARE A EE 21 3 0 DATA R AD AREA e e e a 22 3 7 ISSUING COMMANDS tetett ttrt tt test tt tetr ee teette EEES ENE nene ESEE EEEEEE nene no ornnannnnenenrcnincnnonenoss 24 4 OPERATION OF THE GATEWAY uuu cccccsccsssscscesesececnsssssesesueeseansaseeseeuseenansasesesuenaeanaasssesesnenanans 29 ds SSCANNING SLAVES EE 29 42 SSCANNING TIMES A E EN EE E be eats sacle ce ane Se aac EEE EE ba Gta da EESE 29 4 3 OFFLINE SLAVES uo cccccccccsessssssccccecsssssccsssccscsssssessseccecsesssessssssecsesssessssccecsesseessssssessessesssssseseessessssssesesses 31 5 SPECIFICATIONS aet aaae paa arar aaro N aceacaceceetddacacsanecaeudaesadeeesbedasnedsadeeeccoseansdeataegenecestd 32 6 TROUBLESHOOTING nee see dada 33 MCD 3000 SERIES 4 USER MANUAL MCD 3000 PROFIBUS GATEWAY Table List RE ul Te EE 10 Table 2 PROFIBUS socket pin assignment cooncccincccnoccconocanoncnnnnnnconnn cono cnn nc ran cnr rca 12 EEES NENNEN 14 Table 4 MCD 3000 Local Remote modes c ccceeeeceeeeeencececeeeeeeseaeeeeecaaeceseceeeeeecaeeeesseee
12. D 3000 device to a PROFIBUS network using the PROFIBUS to MCD 3000 gateway The PROFIBUS Master can then control any connected MCD 3000 device start it stop reset trip conditions and read operational status motor conditions ortrip status The PROFIBUS to MCD 3000 Gateway isa certified PROFIBUS slave device A numberof gatewaysand other PROFIBUS slave devices can be connected to the same network subject only to standard PROFIBUS limitations The gateway isa masteron the RS 485 multi drop MCD 3000 communications network Up to 30 MCD 3000 devices may be connected to a single Gateway In thisway up to 30 MCD 3000 devices will share one PROFIBUS address on the PROFIBUS communications network This manual describes how the PROFIBUS to MCD 3000 gateway operates how to connect MCD 3000 series soft starters to the gateway and how to connect and operate the gateway ona PROFIBUS network MCD 3000 SERIES 6 USER MANUAL MCD 3000 PROFIBUS GATEWAY When reading this manual it may help to referto the MCD 3000 Operating Instructions Danfoss document no AM B00000 MCD 3000 SERIES 7 USER MANUAL MCD 3000 PROFIBUS GATEWAY 2 _INSTALING THE GATEWAY 2 1 Gateway connection diagram The diagram below shows how the gateway isconnected to the PROFIBUS network and to the RS 485 sub network PROFIBUS DP Master PROFIBUS network MCD 3000 Gateway DP Slave RS 485 sub network MCD 3000 device
13. Instead you should use SFC 14 to cyclically copy module data to PLC intemal memory and then retrieve the required values In case of problems consult an S7 expert re the memory addresses to be used for motor starter modules and the correct way of retieving module data 3 3 Setting PROABUS 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 supportsall the baud ratesthat the MCD 3000 devices support First Parameter Baud Rate Value 1 200 bps 2 400 bps 4 800 bps 9 600 bps Default 5 19 200 bps Table 7 Gateway parameter RS 485 link baud rate MCD 3000 SERIES 19 USER MANUAL MCD 3000 PROFIBUS GATEWAY The second parameter defines gateway operation if communication with the master stops Second Action on communication parameter breakdown Stop polling MCD3000 devices Lo STOP command sent to all MC D3000 devices 3 COASTTO STOP sent to all devices Table 8 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 Ifthe second parameterisset to 1 the gateway will stop poling MC D3000 deviceson communications breakdown This may cause MCD3000 devices to trip if they are so programmed Para meter 2
14. MCD 3000 PROFIBUS GATEWAY PROHABUS Gateway for MCD 3000 Senes Soft Starters P N FS 1135 User Manual Ver 19 10 October 2003 Copyright 2002 Fieldbus Specialists MCD 3000 SERIES 1 USER MANUAL MCD 3000 PROFIBUS GATEWAY REVISION NOTES Index Date less Author Rev Revision note i 3 10 Mar 2002 All e address A ees correctionsto Specifications el fags Wiring diagramsadded mapping of read memory corrected 5 MAY 2002 1 5 Unified format added functions to ha nd le comm breakdown pa OCT 2002 Added comments related to Siemens S7 PLC a OCT 2003 1 7 Added comments re finmware version 2 02 and code compliance with Danfoss manual AMB00000 Rev G 9 O C T 2003 d Modified to reflect compliance with AMB00000 Rev G 10 O C T 2003 DP 19 Note re byte sequencing in 2 10 TEC HNIC AL SUPPORT In case of any questions or problems please contact Fieldbus Specialists on sales fieldbus com au We will endeavour to reply immediately PREFACE MCD 3000 SERIES 2 USER MANUAL MCD 3000 PROFIBUS GATEWAY 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 asa commitment by Fieldbus Sp ec ia lists Fieldbus Specialists assume no responsibility for any errorst
15. asterto the slave In case ofthe MCD3000 gateway the configuration data instruct the gateway about the number of MCD 3000 devicesto scan about the baud rate on the RS 485 network and about required action if the gateway goes offline on PROFIBUS Master controller genernatesthe configuration data autonomously and the PLC has no control over their transmission or content Process data are the data transmitted cyclically between the masterand slave The PLC writes the data forthe slave to the Write area and readsthe data from the slave from the Read area Locationsof the Write and Read areas in the PLC memory are specific to each PLC Fordetails consult the PLC manual 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 commandsto MC D3000 devices asdescribed later in this manual The first byte is the Master Handshake Register Only the two least significant bits BO and Bl are used the other six bits a re ignored by the gateway Meaning of the value of bits BO and Bl is explained later in this document The second byte isthe Command Register When PROFIBUS master controller issues a command to a MCD3000 device it writes the code of the command to the Command Register Table 9 below showsall the valid values command codes that can be written to the Command Register and the commands associated with these values The values in
16. ate Configuration Options 1 1200 baud 2 2400 baud a 4800 baud AE 9600 baud EE 19200 baud Default Setting 4 9600 baud Table 5 MCD 3000 RS 485 baud rate values Parameter 23 MCD 3000 address for RS 485 serial communications Required Setting A number between 1 and the total number of MCD 3000 devices on the network Table 6 MCD 3000 node address on RS 485 network MCD 3000 SERIES 17 USER MANUAL MCD 3000 PROFIBUS GATEWAY 3 PROGRAMMING THE MASTER CONTROLLER 3 1 GSD file 3 2 Declaring modules Information on the technical characteristics of the gateway is loaded into PROFIBUS master software by meansof a GSD file A flop py disk with the GSD file is supplied with the gateway The GSD file name is FS1135 G SD Follow the instructions in the PROFIBUS config uratio n ma nagement software manual for loading the GSD file and adding the new slave the gateway to the network If you need a copy of the GSD file please contact usat sales fieldbus com au For the PROFIBUS Masterto 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 n load the GSD file for details referto the manual for master configuration software declare the required modules within the gateway set PROFIBUS parameters of the gateway The gateway isa modular PROFIBUS slave consisting of several modules as defined in the GSD file Th
17. d be illuminated at all times whether green or red The PROFIBUS socket of the PROFIBUS to MCD 3000 Gateway must be connected to a PROFIBUS network in accordance with PROFIBUS Technical Guideline Installation Guideline for PROFIBUS DP FMS PROFIBUS Intemational Order No 2 112 The PROFIBUS to MCD 3000 Gateway connection requiresa PROFIBUS cable with DB9 male connector Pin assignment in the PROFIBUS socket is as follows DO socket Pin Purpose ni Shield functional ground Le O Not connected 3 RXD TXD P Data Line Not connected e O Data ground reference potential for VP 6 vP supplyvoltage 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 pinscan be used if needed The gateway doesnot provide termination on the PROFIBUS cable Ifthe gateway is located at either end of the cable the termination resistors should be provided extemally usually in a PROFIBUS plug with the termination option The gateway providestermination power on pins5 and 6 The shield on the PROFIBUS soc ket is galvanically connected to the metal top lid on the enclosure An earthing lug isprovided for earthing the top lid When the PROFIBUS cable plug isin the MCD 3000 SERIES 12 USER MANUAL MCD 3000 PROFIBUS GATEWAY socket the shield on the PROFIBUS cable isconnected with the
18. e Result Ready Bit PROFIBUS Master should read the Command Result Register Control module Read data byte at offset 1 Ifthe command was Read Status Read Status 1 or Read Trip Status PROFIBUS master should 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 asthe four bytesthat MCD 3000 device sends in reply to the equivalent command referto the MCD 3000 device Operating Instructions for details Ifthe command was Read Gateway Finmware Revision PROFIBUS Master should retrieve the content of the Data Read Registers bytes at offsets 6 9 in Control Module The fimware revision is encoded as four ASCII characters Example for Rev 2 02 the content of the fourdata bytes will be 0 0x30 2 0x32 1 0x31 and 0 0x30 Asthe 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 hasbeen read PROFIBUS master must NOTissue a command until the gateway hasacknowledged the previouscommand bits BO in Masterand Slave Handshake Registers are equal whether 0 orl the reply to ithasbeen acknowledged bits B1 in Master and Slave Handshake Registers are equal whether 0 or 1 Status of the motorcan be affected by a number of factors
19. e gateway must be configured with the control module declared first and then with one slave module declared foreach soft starter connected to it The control module has 10 bytes of input data and 3 bytes of output data no consistenc y This module isdeclared in the GSD file with the Preset keyword and many configuration applications will automatically declare it as required and in the correct position asthe first module in the configuration Check that the software you are using supports the Preset keyword and if not declare this module manually as the first one in the configuration data of the gateway In addition to the control module you must declare a slave module 5 Bytes In module consistency foreach MCD 3000 device connected to the gateway The gateway assumes MCD 3000 SERIES 18 USER MANUAL MCD 3000 PROFIBUS GATEWAY that the addresses of the MCD 3000 devices start at land are consecutive up to the numberof expected devices The first motor starter module relates to the MCD 3000 with address 1 the second one to 2and so on Address values are not related to physical positioning of MCD 3000 devices on the RS 485 sub network NOTE for users of SIMATIC S7 Motor starter modules are defined as so called modules with data consistency This is necessary to guarantee accuracy of cunentreading The consequence of itin S7 is that module data cannot be read directly direct reading always retums 0
20. e second byte at offset 1 camesthe code of the outcome of the command 1 forsuccess erorcodes2 3 or4 in case of failure see the table below for details Resultcode Description 1 Suc cessful completion 2 The gateway rejected the command invalid command code ordata 3 No reply from the target ortarget rejecting the command 4 Invalid target address Table 10 Command result codes The next four bytes at offsets 2 to 5 cany information about network status of devices on the RS 485 sub network The first byte at offset 2 relatesto addresses 1 8 the second to 9 16 the third to 17 24 and the fourth to 25 30 Fourbytes are always reserved imespective of the number of slaves present When bit BO in byte at offset 2 is set it indicates that the MCD3000 device with address 1 is present and MCD 3000 SERIES 22 USER MANUAL MCD 3000 PROFIBUS GATEWAY communicating Simila dy bit B1 set indicates slave 2 present A bit set to O means that the corresponding slave isnot present ornot 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 commandsthat retum data such as Request Status The content of these bytes is the same asthe content of the data part of a reply received from the MCD3000 devices
21. eeseaeeeesseeeesenuseerseaes 17 Table 5 MCD 3000 RS 485 baud rate values rra nannnnnnranrn near nraninnnss 17 Table 6 MCD 3000 node address on RS 485 network non cn ran carnn cnn narran 17 Table 7 Gateway parameter RS 485 link baud rate oooconooccccnnoccccnonoocononanonononononnnnnnoncnnnnnn cnn nonnnnnn naar nnnnn nn nnannnss 19 Table 8 Gateway parameter gateway operation on communication lOSS ooooconoccccnnnoccccononacnnononnnnnnnnannnnonnnnnn 20 Table 9 PROFIBUS Write Out Memory in Control module conocio nn corona rnn crac 22 Table 10 Command result COS cccccesccceeeenceeeeeneeeeessaeecescaeeeesceaeeeescaaeeeseeaeeeeeeaeeesssaeeeescaeesesnsesessenseeessaes 22 Table 11 PROFIBUS Read In memonm cnn cnn nnn nro n creen 24 Table 1 2 Valld COMMANOS E 25 Table 13 New Command Command Acknowledge handshaking nc nanccnancncnnno 27 Table 14 Result Ready Result Acknowledge bandebakimg AAA 27 Table 15 Scanning cycle length for different baud rates and the number of MCD 3000 devices present 30 Table 16 Maximum time to detect return of an offline device A 30 Table 17 Gat way specifiCations ina adn 32 Table 18 Troubleshooting Ee te LEE 33 Figure List Figure 1 Typical diagram of a PROFIBUS network a gateway and an RS 485 sub network cceeceeeseeeenees 8 Fig re 2 Gateway front pane 080 hn as 9 Figure 3 Entering address via dip Switches an example c
22. esscceeesseceeeeeneeeeeseneeeeeeaeeeesenaeeeeneeaeeeeeeaeesenaaeeeees 13 Figure 4 Recommended wiring diagram for one MCD3000 device cooooconccccnocinaccccnonanonaconancnnancn nana ccoo nc nnncnnnn cnn 15 Figure 5 Wiring diagram for a number of MCD3000 devices connected to a single gateway 15 MCD 3000 SERIES 5 USER MANUAL MCD 3000 PROFIBUS GATEWAY 1 INTRODUCTION 1 1 Important user information 12 General This manual describes operation and programming of a PROFIBUS gateway for MC D3000 series soft starters gateway firmware revision 2 11 Gateway with firmware version 2 11 complies with M C D3000 protocol asdescribed in Danfoss manual AMB00000 Rev G and islikely to be incompatible with earlier versions of the soft starter Remote programming of parameters is not supported atthe moment Contact Fieldbus Specialists if you require a firmware version that supports ea dier models Observe all the necessary safety precautions when contolling any MCD 3000 series device over the serial communications link including alerting personnel that the machinery may start without waming The MCD 3000 series of solid state soft starters incorporate a serial communications facility that allows forthe remote control and interrogation of the MCD 3000 from an intelligent host master via a multi drop RS 485 communications network using a proprietary protocol specific to MCD 3000 devices The RS 485 link may be used to interface a MC
23. fa MCD 3000 device that was declared offline becomes available again The Table 16 above shows the worst case time for detecting sucha device assuming that only one device on the network is offline The time isin seconds Since up to 30 slaves can share the same RS 485 serial link it is critical that communication dela ys are kept to a minimum Slavesthat 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 Ifa slave failsto respond to a command it is considered an offline slave and joinsa list of offline slaves intemal to the gateway Ineach polling cycle all online slavesare polled After 5 polling cycles a command issent to one of the offline slaves Ona subsequent offline slave poll the next slave on the list of offline slaves is polled Once an offline slave respondsto a command it isno longerconsidered an offline slave This mechanism helps keep network delaysto a minimum while also being able to recover offline saves when they come online The above mechanism allowsto connect disconnect MCD 3000 devices while the network is working with minimal impact on the rest of the network MCD 3000 SERIES 31 USER MANUAL MCD 3000 PROFIBUS GATEWAY 5 SPECIAHCATIONS Mounting PROABUSInterface po ae MC D3000 Subnetwork Interface Pee ee Voltage 3 2 Watts
24. hat may appearin this document Although this product hasbeen developed with great care and extensively tested Fieldbus Specialists cannot guarantee the suitability of this product forany purpose Warranty claims shall be limited to the right to require rectification of faults Lia bility forany damages which may have arisen from the use of this product or its documentation shall be limited to cases of intent MCD 3000 SERIES 3 USER MANUAL MCD 3000 PROFIBUS GATEWAY CONTENTS 1 INTRODUCTION WEE 6 1 1 IMPORTANT USER INFORMATION ooccccccccococononononononononononononononononononononononononononnnnnnnnnononononononononenenenenecenanesos 6 12 GENERA A okie BAM e A Ed EE E BM AM e o Ad 6 2 INSTALING THE GATEWAY oocccccccoconnnonococconananananoncnnananananrnccnnnnnnananan rr ncnnan anna nr n rr KREE naaa r rra nnmnnn nnna 8 2 1 GATEWAY CONNECTION DIAORAM ttt ttt t e e e e e e e e e e EEE EEEE rerene 8 DR FRONT PANEL ERE A E EE E E E e 9 PR E INSTALIMATION SEQUENCE tec AM E e cat kd oka BMRA a ce E E e a 11 2 4 POWER CONNECTION 35 c5ccdicscecocecsceceseascccdescscecogeasdececeasceecseusaecdecescesodsasdecocececesedsssdecdedeccesedsssiecocesscessibaes 11 2 9 PROFIBUS CONNECTION et ees ee SEENEN EE idas 12 251 CabIING EE 12 2 2 GATEWAY CONFIGURATION Ee a 13 2 6 MCD3000 CONNPCTION nene ncorononnanenoncnrnnonnanennnccnccnnnnnnnnss 14 PA S REE EE let WEE 14 2 6 2 MCD3000 CONFIQUIATION ENEE 16 3 PROGR
25. ication on the RS 485 link Occasional errors on the RS 485 link G G Both PROFIBUS and RS 485 links operational and error free Legend B LEDoff G LED steady green R B LED flashing red off G R LEDflashing 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 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 MCD 3000 SERIES 10 USER MANUAL 2 3 Installation sequence 2 4 Powerconnection MCD 3000 PROFIBUS GATEWAY 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 forone 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 addresson the gateway and addresssetting in the master If the LED flashes green red verify the configuration of modules in the PROFIBUS master Do not proceed further until you get the PROABUS LED steady green Configure and connect the first MCD 3000 device set it t
26. k for address 2 5 byte block for address 30 3 7 Issuing Commands MCD 3000 PROFIBUS GATEWAY Offset Contents Comments 0 Slave Handshake Bit Bit BO Command Ackn Bit Register Bit Bit B1 Result Ready Bit Command Result 1 Success Register 2 Invalid rejected Command 3 No rejected response from slave 4 Invalid slave Address Online Slaves Register Bit BO Slave 1 online 1 Bit B7 Slave 8 online Online Slaves Register Slave 9 online Slave 16 online 2 Online Slaves Register Slave 17 online Slave 24 online 3 Online Slaves Register Slave 25 online Slave 30 online 4 Data Read Registers Command Data Repl Status for address 1 Status 1 value for device at address 1 Trip foraddress 1 Trip value fordevice ataddress 1 12 13 Curentforaddress1 Motor Current O 9999 Amps 14 Temperature for Motor Thermal Capacity O 250 address 1 15 Statusforaddress2 16 Tipforaddress2 17 18 Curentforaddress2 Asabove 19 Temperature for Asabove address 2 Status for address 30 Trip foraddress 30 Asabove 30 159 Temperature for Asabove address 30 Table 11 PROFIBUS Read In memory 69 PROFIBUS master can issue commandsto each MCD 3000 at any time The following Table 12 lists the commandsas well as the purpose of these commands The commandsare shown in hexadecimal notation MCD 3000 SERIES 24 USER MANUAL MCD 3000 PROFIBUS GATEWAY Command Acti
27. o address 1 see section 2 6 fordetails On success the RS 485 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 Lateron you can increase the numberof MCDs If the RS 485 status LED stays solid red check the RS 485 cable the MCD 3000 device configuration set to Local wiring to MCD 3000 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 3000 devices make also the relevant changes to the configuration of PROFIBUS master On successthe RS 485 LED should go solid green If it flashes green red one or more MCD 3000 doesnot communicate with the gateway 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 it is 240mA for 12V and 90mA for 32V The powerconnectorisa 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 MCD 3000 SERIES 11 USER MANUAL 2 5 PROABUS connection 2 5 1 Cabling MCD 3000 PROFIBUS GATEWAY Presence of correct powercan be venfied by looking at the LEDs on the front panel at least one LED shoul
28. on OxB4 Reset Trip State Read Temperature OXFF Read Gateway Firmware Revision Table 12 Valid commands This isthe 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 Oto 1 orfrom 1 to 0 so that it is different from the Command Acknowledgment Bit in Save Handshake Register Then the following happens The gateway togglesthe Command Acknowledge Bit in Slave Handshake Register Control module Read data byte at offset 0 to make it the same asthe Command Request Bit This indicatesan acknowledgement of the command but not its completion When the command processing hasfinished whether suc cessfully or not the gateway places the results into the Command Result Register Control module Read data 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 aswell asthe availability of the results MCD 3000 SERIES 25 USER MANUAL MCD 3000 PROFIBUS GATEWAY This ishow Mastercan read the outcome of the command Upon detecting change of value of th
29. opine gateway Figure 5 Wiring diagram fora number of MC D3000 devices connected to a single gateway MCD 3000 SERIES 15 USER MANUAL MCD 3000 PROFIBUS GATEWAY Ifa number of MCD3000 devices are connected to a single gateway we recommend wiring them in senes see fig 5 The cable should constitute a single line without side branches Note that we recommend connecting GND points 61 on all MCD 3000 devicesto 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 ma y not be necessary to connect points 61 RS 485 interface on MCD3000 is not galvanically isolated Failure to equalize ground potential on MCD 3000 devices connected via RS 485 link may result in their damage 2 6 2 MC D3000 configuration The gateway can communicate at any of the baud ratesthat MCD 3000 devicescan support All MCD 3000 devices connected to the same sub network must be configured for the same baud rate Each MCD 3000 device must be configured with a node address Each must have a different addressand each address must be in the range 1to the numberof MCD 3000 devicesconnected to the gateway inclusive Example if four devicesare connected to a gateway they must have addresses 1 2 3 and 4 Each MCD 3000 Local Remote Mode parameter Parameter 20 must be setto 0 Lord Setting this parameter to 3 disables the RS 485 communications port Fo
30. pdates the PROFIBUS process Read data in an autonomous fashion Status 1 and Trip Code are being read most frequently in each scan cycle Curent isread once every third scan cycle and Temperature every tenth scan cycle On the first scan the Status _1 Trip Code Current and Temperature are read from all declared devices The device network status bits in the Read area offset 2 5 are set forall slaves that reply referto Table 11 The addressing scheme forthe MCD 3000 Soft Starters assumes that the node addresses of all the MCD 3000 devices are in the range from 1 up to the number of devices preset in the configuration Devices with higher addressesare not scanned Ifa slave fails to respond to a data request command it is considered an Offline Slave and hasit s corresponding network status bit cleared Also cleared are the process data bytes related to this sla ve Note that Status 1 Tip code Current and Temperature processdata foreach 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 The following Table 16 givesan indication of the time required to complete a polling cycle fora number of saves present on a serial link overthe supported baud rates The timesare in seconds These figures indicate possible dela y in detecting changesto Status 1 and Trip code data read in each
31. place Some device addresses are set incorrectly Incorrect gateway configuration information in PROFIBUS Master PROFIBUS Master issues invalid command request Table 18 Troubleshooting guide MCD 3000 SERIES 33 USER MANUAL
32. r more detailed explanation referto the MCD 3000 Operating Instructions MCD 3000 devices must be set for Local operation using the Local Remote pushbutton on the front panel When thisis done the LED labeled REMOTE on the front panel is off NOTE When the MC D3000 device is set for Remote it does not execute commands received over the RS 485 link However it stll acknowledges these commands Consequently the gateway and the PROABUS master cannot detect this condition Forworking 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 MC D3000 device being set for Remote accidentally or by mistake The MCD 3000 devices must be configured using the keypad LCD display on its front panel The method of setting MCD 3000 SERIES 16 USER MANUAL MCD 3000 PROFIBUS GATEWAY parameters is described in details in the MCD 3000 Series Soft Starter Operating Instructions The following tables show the required configuration for the MCD 3000 soft starter parameters relevant to the operation of the gateway Parameter 20 Local Remote Mode Configuration Options O Local Remote enabled 1 Local Remote enabled only when motorstopped po 2 boca contro only 3 Remote control only Default Setting O Local Remote enabled Table 4 MCD 3000 Local Remote modes Parameter 22 Serial communication baud r
33. the table are shown in hexadecimal These values have been chosen to resemble the original command codesasused by MCD3000 devices Forexample the ASCII command code for Stop is B12 The hexadecimal value selected for Stop is B2 hex OxB2 in C language notation and 1011 0010 in binary The third byte Address Register contains the RS 485 sub network address of the MCD device that the command is for MCD 3000 SERIES 21 USER MANUAL 3 6 Data read area MCD 3000 PROFIBUS GATEWAY Offset Contents Comments Master Bit BO New Command Bit Handshake Bit B1 Result Acknowledge Bit Register Command see Table 12 below Register 2 Slave Address Address of the slave that the Register command is for Table 9 PROFIBUS Write Out Memory in control module 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 3000 devices 4 bytes for each MCD 3000 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 O and the subsequent bytes within the module follow The first byte in the control module offset O Slave Handshake Register operates in the way similarto the Master Handshake Register Only the bits BO and Bl are used More detailed explanation can be found later in this document Th
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