Danfoss OPTC3 C5 VACON NXP Air Cooled Installation Guide

Danfoss OPTC3 C5 VACON NXP Air Cooled

GENERAL

The Vacon NX AC drives can be connected to the Profibus DP using a fieldbus board. The drive can then be controlled, monitored and programmed from the Host system. The Profibus fieldbus board is installed in slot E on the control board of the AC drive.

WARNING!
Internal components and circuit boards are at high potential when the AC drive is connected to the power source. This voltage is extremely dangerous and may cause death or severe injury if you come into contact with it.

NOTE! You can download the English and French product manuals with applicable safety, warn-ing and caution information from http://drives.danfoss.com/knowledge-center/technical-documentation/.

PROFIBUS DP OPTION BOARD TECHNICAL DATA

General

Profibus DP connections| Interface| OPTC3 : Pluggable connector (5.08mm) OPTC5 : 9- pin DSUB connector (female)
---|---|---
Data transfer method| RS- 485, half-duplex
Transfer cable| Twisted pair (1 pair and shield)
Electrical isolation| 500 VDC
Comm unications| Profibus DP| As described in the document “ Profibus Profile for var iable speed drives, Profidrive”
PPO types| 1, 2, 3, 4, 5
Baud rate| 9.6 kbaud to 12 Mbaud
Addresses| 2 to 126
Envir onment| Ambient operating temperature| –10°C…55°C
Storing tempera-

ture

| –40°C…70°C
Humidity| <95%, no condensation allowed
Altitude| Max. 1000 m
Vibration| 0.5 G at 9…200 Hz
Safety|  | Fulfils EN50178 standard

Profibus cable

1. Profibus devices are connected in a bus structure. Up to 32 stations (master or slaves) can be connected in one segment. The bus is terminated by an active bus terminator at the beginning and end of each segment (see Figure 2-1). To ensure error-free operation, both bus terminations must always be powered. When more than 32 stations are used, repeaters (l ine amplifiers) must be used to connect the individual bus segments.

The maximum cable length depends on the transmission speed and cable type (see Table 2-3). The specified cable length can be increased using the repeaters. The use of more than 3 repeaters in series is not recommended.

12000

---|---|---|---|---|---|---|---
Length l ine A (m)| 1200| 1200| 1200| 1000| 400| 200| 100
Length l ine B (m)| 1200| 1200| 1200| 600| 200| –| –

The following cables can be used:

NOTE!

1. The minimum distance between power and bus cables is 30 cm.
2. A minimum cable length of 1 m between two stations is recommended.

PROFIBUS DP

Introduction
Profibus is a vendor-independent, open-field standard for a wide range of applications in manu-facturing, process and building automation. Vendor independence and openness are guaranteed by the Profibus standard EN 50 170. With Profibus, devices of different manufacturers can communicate without special interface adjustments. Profibus can be used for both high-speed time- critical data transmission and extensive complex communication tasks. The Profibus family consists of three compatible versions.

Profibus DP
Optimized for high-speed and inexpensive hookup, this Profibus version is designed especially for communication between automation control systems and distributed I/O at the device level. Profibus-DP can be used to replace parallel signal transmission with 24 V or 0 to 20 mA.

Profibus PA
Profibus PA is designed especially for process automation. It permits sensors and actuators to be connected on one common bus line even in intrinsically- safe areas. Profibus PA permits data communication and power over the bus using a 2-wire technology according to the international standard IEC 1158-2.

Profibus FMS
Profibus FMS is the general-purpose solution for communication tasks at the cell level. Powerful FMS services open up a wide range of applications and provide great flexibility. Profibus FMS can also be used for extensive and complex communication tasks.
Profibus specifies the technical and functional characteristics of a serial fieldbus system with which decentralized digital controllers can be networked together from the field level to the cell level. Pro-fibus distinguishes between master devices and slave devices.
Master devices determine the data communication on the bus. A master can send messages without an external request when it holds the bus access rights (the token). Masters are also called ‘active stations’ in the Profibus protocol. Slave devices are peripheral devices. Typical slave devices include input/output devices, valves, drives and measuring transmitters. They do not have bus access rights and they can only acknowledge received messages or send messages to the master when requested to do so. Slaves are also called ‘passive stations’.

Profiles
The Profibus DP protocol defines how user data are to be transmitted between the stations over the bus. User data are not evaluated by the Profibus DP transmission protocol. The meaning is specified in the profiles. In addition, the profiles specify how Profibus DP is to be used in the application area. The following Profibus DP profile is used in the VACON NX Profibus Fieldbus board.

Variable Speed Drive Profile (3.071)
Leading manufacturers of drive technology have jointly defined the PROFIDRIVE profile. The profile specifies how the drives are to be parameterized and how the setpoints and actual values are to be transmitted. This enables drives from different vendors to be exchanged. The profile contains the necessary specifications for speed control and positioning. It specifies the basic drive functions while leaving sufficient freedom for application-specific expansions and further developments. The profile describes the mapping of the application functions for DP or FMS.

PROFIBUS FIELDBUS BOARD LAYOUT AND CONNECTIONS

The Vacon Profibus Fieldbus Board is connected to the Fieldbus through either a 5-pin pluggable bus connector (board OPT-C3) or a 9-pin female sub-D-connector (board OPT-C5). The communication with the control board takes place through the standard Vacon Interface Board Connector.

NOTE! The OPT-C3/C5 option board has two hardware versions. These two hardware versions have different layouts, grounding settings, and firmware packages and they use different tools for firmware updating. The OPT-C3/C5 hardware version number can be read from the bottom side on the bottom left of the option board PCB (see Figure 4-1).

Correct firmware must be used for different hardware, incorrect firmware cannot be loaded into un-supported hardware. See Table 4-1 for firmware support on different hardware.

Hardwar e version| Firmware name| Package| Load tool
---|---|---|---
PC00257| 10502 Vxxx| .VCN| NCLoad
PC01294| FW0232 Vxxx| .VCX| Vacon Loader

NOTE! FW0232 is designed to be compatible with the 10502 firmware. The only difference is that Vacon Loader must be used for firmware updates. Vacon Loader is supported in the NX products which use firmware mentioned in Table 4-2. Older NX firmware versions support only the NCLoad tool, and therefore updating of the PC01294 OPT-C3/C5 firmware is not possible unless the NX firmware is updated.

• NX product board ID can be read using NC Drive:
  • Drive -> Info -> “Control Card Serial Nr:” -> 761… / 661… / 752…
• NX firmware version can be read using NC Drive or keypad:
  • NCDrive: Drive -> Info -> “VCN name”
  • Keypad: 6.8.3.1 – System menu -> System info -> Software -> Software package

Profibus OPT-C3 option board

Grounding of bus cable shield in OPT-C3
The bus cable shield can be grounded in three different ways:

• directly to the AC drive frame
• to the frame of the AC drive through an RC filter
• clamping the cable to the converter frame (recommended)

NOTE! Normally, the option board has already been installed in slot E of the control board. It is not necessary to detach the whole board for the grounding of the bus cable shield. Just detach the terminal block.

Grounding the bus cable shield directly to the AC drive frame

1. Set jumper settings depending on the used hardware version:
   • PC00257: Set jumper X1: Cable shield is connected directly to PE

Strip about 5 cm of the Profibus cable as shown in the picture.

NOTE! Do the same for both bus cables (except for the last device). However, since the grounding is done on one cable only, cut off the exposed part of the other grounding cable.

Leave no more than 1 cm of the red and green data cable outside the terminal block and strip the data cables at about 0.5 cm to fit in the terminals. See the pictures below.

NOTE! Do this for both bus cables.

We recommend you to use an Abico connector to fit the grounding cable into the grounding terminal (#1). Inser t the red and green data cables of both Prof bus cables into terminals # 3 (red) and #4 (green).

Place the Profibus board into slot E of the control board (see board installation on page 22) and fix both the Profibus cables on the frame with the clamp.

Grounding the bus cable shield directly to the AC drive frame using an RC filter

We recommend you to do the grounding in this manner when the distance between the devices exceeds 50 meters (55 yds.). When the distance between the devices is long, disturbances (e.g. voltage spikes) are more likely to appear. In this grounding method, the disturbances are filtered out. Even if the ground planes of A, B and C are different (which is very typical e.g. in construction) there is no current between them because the points do not have a ground connection.

NOTE
If a potential difference occurs between the grounding points, equalization current can flow through a shield connected at both ends. In this case, install an additional potential equalization line and set this jumper X1 in ON position.

• Carry out the grounding in the same way as advised in Chapter 4.1.1.1.

Grounding by clamping the cable to the converter frame
This manner of grounding is the most effective and especially recommended when the distances between the devices are relatively short (see 4.1.1.2). In this manner of grounding, the position of jumper X1 or X13/14 is of no importance .

1. Strip about 5 cm of the Profibus cable in the same way as shown in Figure 4-5 but cut off the grey cable shield. Remember to do this for both bus cables (except for the last device).

2. Leave no more than 1 cm of the red and green data cable outside the terminal block and strip the data cables at about 0.5 cm to fit in the terminals. See Figure 4-6 and Figure 4-7.
   NOTE! Do this for both bus cabels.

3. Insert the red and green data cables of both Profibus cables into terminals # 3 (red) and #4 (green). See Figure 4-8.

4. Strip the Profibus cable at such a distance from the terminal that you can fix it to the frame with the grounding clamp. See Figure 4-14.

5. Ground the cable shield at both ends and on all loads by 360° connection.

Profibus OPT-C5 option board

The following connectors can be used (180° cable outlet):

• Phoenix SUBCON-PLUS-PROFIB/AX/SC 27 44 38 0
• Siemens Profibus connector 6GK1 500-0EA02

Grounding of a D- connector

Bus terminal resistors
If Vacon is the last device of the PROFIBUS line, the bus termination must be set. Use jumper X6/X13 (ON position) or external termination resistors (e.g. in DSUB-9 connector ). See Figure 4-19 or Figure 4-20 depending on the used OPT-C3/C5 hardware.

NOTE! Terminat ion works properly when the drive has power (active termination) connected.

LED indications

The LED indications next to the connector show the present status of different modules:

• PS: PROFIBUS communication status (red LED)
• BS: PROFIBUS board status (yellow led)
• FS: Fieldbus status (green led)

The LEDs are orientated differently between hardware versions. See Figure 4-21 or Figure 4-22 depending on the used hardware.

Profibus status LED (PS) / RED

·          Data exchange between Master and Slave

ON| Profibus communication is broken or not started.

·          Bus cable broken or incorrectly connected

·          Wrong configuration or parametrization data of Master

·          Master is off l ine or shut down

Profibus board status LED (BS) YELLOW

the AC drive
Blinking fast (once/sec)| Option board is activated and in RUN state

·          Option board is ready for external communication

Blinking slow

(once/5 secs)

| Option board is activated and in FAULT state

·          Internal fault of option board

Fieldbus status LED (FS) GREEN

·          No external communication

ON| Fieldbus module is activated

·          Parameters received and module activated

·          Module is waiting for messages from the bus

Blinking fast (once/sec)| Module is activated and receiving messages from the bus
Blinking slow

(once/5 secs)

| Module is in FAULT state

·          No messages fr om Master within the watchdog time

·          Bus broken, cable loose or Master off l ine

INSTALLATION OF VACON NX PROFIBUS BOARD

NOTE
It is not al lowed to add or replace option boards or fieldbus boards on an AC dr ive with the power switched on! This may damage the boards.

COMMISSIONING

First, read chapter 8, Commissioning and additional instructions in the Vacon NXS/P User Manual.

Fieldbus board parameters
The Vacon Profibus board is commissioned with the control keypad by giving values to appropriate parameters in menu M7 (for locating the expander board menu see Vacon NXS/P User Manual , Chapter 7).

Expander board menu (M7)
The Expander board menu makes it possible for the user 1) to see what expander boards are connected to the control board and 2) to reach and edi t the parameters associated with the expander board. Enter the fol lowing menu level (G# ) with the Menu button right. At this level, you can browse through slots A to E with the Browser buttons to see what expander boards are connected. On the lowermost line of the display, you also see the number of parameter groups associated with the board. If you still press the Menu button right once you will reach the parameter group level where there are two groups: Editable parameters and Monitored values. A further press on the Menu button the right takes you to either of these groups.

Profibus parameters
To commission the Profibus board, enter the level G7.5.1.# from the Parameters group (G7.5.1). Give desired values to all Profibus parameters (see Figure 6-1 and Table 6-1).

2 – 19.2 kBaud

3 – 93.75 kBaud

4 – 187.5 kBaud

5 – 500 kBaud

6 – 1.5 Mbaud

7 – 3 MBaud

8 – 6 Mbaud

9 – 12 Mbaud

10 – AUTOMATIC

| Communication speed in baud
3| PPO TYPE|  | 1 – PPO1

2 – PPO2

3 – PPO3

4 – PPO4

5 – PPO5

| Parameter, CW/ SW, Ref/Act

Parameter, CW/ SW, Ref/Act, PD1- PD4 CW/SW, Ref/Act

CW/SW, Ref/Act, PD1- PD4

Parameter, CW/ SW, Ref/Act, PD1- PD8

4| OPERATE MODE|  | 1 – PROFIDRIVE

2 – BYPASS

3 – ECHO

| Use the mode ” PROFIDRIVE” with standard applications

The parameters of every device must be set before connecting to the bus. Especially the parameters “SLAVE ADDRESS” and “PPO TYPE” must be the same as in the master configuration.

Profibus status
To see the present status of the Profibus fieldbus, enter the Profibus status page from the Monitor menu (G7.5.2). See Figure 6-2 and Table 6-2 below .

Profibus status

• 0 Waiting parameter from Master
• 1 Waiting configuration from Master
• 2 Communication established

Table 6-2. Profibus status indications

Start-up test

AC drive application
Choose Fieldbus (Bus/Comm) as the active control place (see Vacon NXS/P User Manual, Chapter 7.6).

Master Software

1. Set Control Word value to 0hex.
2. Set Control Word value to 47Fhex.
3. AC drive status is RUN
4. Set the Reference value to 5000 (=50.00%).
5. The Actual value is 5000 and the AC drive output frequency is 25.00 Hz
6. Set Cont rol Word value to 477hex.
7. AC drive status is STOP

If Status Word bit 3 = 1 Status of AC drive is FAULT.

PROFIBUS-VACON NX INTERFACE

Features of the Profibus-Vacon NX inter-face:

• Direct control of Vacon NX ( e.g. Run, Stop, Direction, Speed reference, Faul t reset)
• Full access to all Vacon NX parameters
• Monitor Vacon NX status (e.g. Output frequency, Output current, Faul t code)

General
Data transfer between Profibus DP master and slave takes place via the input/output data field. The Master writes to Slave’s output data and the Slave answers by sending the contents of its input data to the Master. The contents of the input/output data are defined in the device profile. The device profile for AC drives is PROFIDRIVE. The Vacon NX AC drive can be controlled by Profibus DP Master using the PPO- types defined in Profidrive (see Chapter 7.3). When Fieldbus has been selected as the AC drive’s active control place, the AC drive’s operation can be controlled from the Profibus DP Master. Whether or not the active control place is fieldbus, the AC drive can be monitored and its parameters set by the Profibus DP Master .

Operat ion mode
The parameter Operation mode (G7.5.1.4, see above) defines how the input/output data is handled on the option board.

PROFIDRIVE

• Data transfer fol lows the document Profibus Profile for variable speed drives, PROFIDRIVE.

BYPASS

• The information of the Process Data field is transferred to the application interface without handling
• Parameter setting takes place according to the Profidrive definition

ECHO

• The OUTPUT data written by the Master is echoed back to the Master in the INPUT field
• The data is not shown in the AC drive but the echoing is carried out on the option board
• This mode can be used when the function of the bus connection is tested

PPO types
PPOs (Parameter /Process Data Object) are the communication objects in PROFIBUS DP.

The PPOs in Vacon NX:

Process data
The process data field is used to control the device (e.g. Run, Stop , Reference, Faul t Reset) and in reading quick actual values (e.g. Output frequency, Output current, Faul t code). The size of the field var ies between 2…20 bytes. The field is structured as fol lows: Process Data Master -> Slave (max 20 bytes)

The use of process data depends on the application. In a typical situation the device is started and stopped via the ControlWord (CW) written by the Master and the Rotating speed is set with Reference (REF). Via PD1…PD8 the device can be given other reference values (e.g. Torque reference). With the help of the StatusWord (SW) read by the Master, the status of the device can be seen. Actual Value (ACT) and PD1…PD8 show the other actual values. See Figure 7-2 .

Control word

The Control command for the state machine (see Figure 7-3.) The state machine describes the device status and the possible control sequence of the AC dr I’ve. The control word is composed of 16 bits that have the following meanings:

With the help of the control word, star t and stop commands can be given to the device. Also, a fault can be acknowledged.

bit 7 = 1

| A rising edge to bit 7

As shown above, there are several stop modes. It depends on the operating situation, and which mode is selected.

NOTE! In Vacon NX AC dr ive STOP1 and STOP3 are identical. Also, STOP2 and RUN DISABLE are identical. Commands STOP1 and STOP3 can be used only with either one of the motor control modes (P2.6.1) Frequency control or Speed control selected and the fieldbus selected as the control place.

Status word

Information about the status of the device and messages is indicated in the Status word. The Status word is composed of 16 bits that have the fol lowing meanings:

• Comes straight from the AC drive
• Bits of the State Machine

State machine
The state machine describes the device status and the possible control sequence of the AC dr I’ve. The state transitions can be generated by using the “Control word” . The “Status word” indicates the current status of the state machine. The modes INIT, STOP, RUN and FAULT (see Figure 7-3.) correspond to the actual mode of the AC drive.

Reference 1

This is the reference 1 to the AC drive. Used normally as Speed reference. The allowed scaling is –10000…10000. In the application, the value is scaled in percentage of the frequency area between set minimum and maximum frequency.

• -10000 = 100.00 % (Direction reverse)
• 0 = 0.00 % (Direction forward)
• 10000 = 100.00 % (Direction forward)

Actual value 1

This is the actual value from the AC drive. Used normally as Speed reference, with the value between –10000…10000. In the application, the value is scaled in the percentage of frequency area between set minimum and maximum frequency.

• -10000 = 100.00 % (Direction reverse)
• 0 = 0.00 % (Direction forward)
• 10000 = 100.00 % (Direction forward)

PD1…PD8
ProcessData Master -> Slave

The Master can write a maximum of 8 additional setting values to the device with the help of the Process Data. How these setting values are used is totally dependent on the application in use.

ProcessData Slave - > Master

The master can read the AC dr ive’s actual values using the process data var iables. Depending on the used appl ication, the contents are either standard or can be selected with a parameter.

Parameter data
The Vacon variables and fault codes as well as the parameters can be read and written using PPO types 1, 2 and 5. The reading and writing can be done via the parameter field of the Profibus message frame. The device parameters can be read and written and the actual values read with the help of the parameter field. The size of the parameter field is 8 bytes and it is divided into three parts, ID, Index and Value.

The parameter addresses are determined in the application. Every parameter and actual value has been given an ID number in the application. The ID numbering of the parameter as well as the parameter ranges and steps can be found in the application manual in question. The parameter value must be given without decimals. The ID numbers of each parameter /actual value are found in the application manual. The ID numbers are grouped as follows:

Parameter field

• Task and parameter ID

Request/Response types

Example messages

FAULT TRACKING

The table below presents the faul ts related to the Profibus option board. For more information, see also Vacon NXS/P User Manual , Chapter 10. The Prof ibus opt ion board status LEDs have been descr ibed in more detail in Chapter 4.4.

Faul t code| Faul t| Possible cause| Correcting measures
---|---|---|---
37| Device change| The option board changed.| Reset
38| Device added| Option board added.| Reset
39| Device removed| The option board was removed.| Reset
40| Device un-known| Unknown option board.|
53| Fieldbus fault| The data connection between the Profibus Master and the Profibus option board is broken| Check the installation.

If installation is correct contact the nearest Vacon distributor.

54| Slot fault| Defective option board or slot| Check the board and slot.

Contact the nearest Vacon distributor.

Table 8-1. Profibus option board faults

You can define with parameters how the AC drive reacts to certain faults:

Code| Par ameter| Min| Max| Unit| Step| Default| ID| Note
---|---|---|---|---|---|---|---|---

P2.7.22

|

Response to fieldbus fault

|

0

|

3

|  |

1

|

0

|

733

| 0 =No response 1 =Warning

2 =Fault,stop acc. to 2.4.7

3 =Fault,stop by coasting

P2.7.23

|

Response to slot fault

|

0

|

3

|  |

1

|

0

|

734

| 0 =No response 1 =Warning

2 =Fault,stop acc. to 2.4.7

3 =Fault,stop by coasting

TYPE FILES

GSD-file (“Profibus Support Disk” files: vac29500.GSD, vac29500.GSE)

APPENDIX

Process Data OUT (Slave → Master)
The Fieldbus master can read the AC drive’s actual values using process data variables. Basic, Standard, Local/Remote, Multi-Step, PID control and Pump and fan control applications use process data as follows:

The Multipurpose application has a selector parameter for every Process Data. The monitoring values and drive parameters can be selected using the ID number (see NX All in One Application Manual, Ta-bles for monitoring values and parameters). Default selections are as in the table above.

Process Data IN (Master - > Slave)
ControlWord, Reference and Process Data are used with All-in-One applications as follows:  Basic, Standard, Local/Remote, Multi-Step applications

Fault reset Com-

mand

| –| –
PD1 – PD8| Not used| –| –

Multipurpose control application

PID control and Pump and fan control applications

troller

| %| 0.01%
PD4–PD8| Not Used| –| –

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Vacon Ltd
Member of the Danfoss Group Runsorintie 7 65380 Vaasa Finland

References

• Engineering Tomorrow | Danfoss

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