Danfoss vacon, opte2, opte e8 User guide

vacon

ac drives

opte2/e8

rs485 multiprotocol option board

installation manual

vacon • 3

TABLE OF CONTENTS

Document: DPD01780C

Release date : 7/1/19

1. Safety...............................................................................................................5

1.1 Danger................................................................................................................................5

1.2 Warnings ............................................................................................................................6

1.3 Grounding and earth fault protection ................................................................................7

2. General ............................................................................................................8

3. Option board technical data .............................................................................9

3.1 General...............................................................................................................................9

3.2 New features ......................................................................................................................9

4. Layout and connections..................................................................................10

4.1 OPTE2 (screw plug) option board layout .........................................................................10

4.2 OPTE8 (Sub-D9) option board layout ...............................................................................11

4.3 LED indications ................................................................................................................12

4.4 Jumpers ...........................................................................................................................12

4.5 Bus terminal and bias resistors ......................................................................................13

5. Cabling instructions .......................................................................................15

5.1 Selecting cable.................................................................................................................15

5.2 Setting the termination resistance..................................................................................15

5.3 Shield grounding options .................................................................................................15

5.3.1 Shield grounding when equipotential bonding is good ...................................................15

5.3.2 Shield grounding when equipotential bonding is poor....................................................16

6. Installation.....................................................................................................17

6.1 Installation in VACON® 20 ...............................................................................................18

6.1.1 Enclosures MI1, MI2, MI3.................................................................................................18

6.1.2 Enclosures MI4, MI5.........................................................................................................21

6.2 Installation in VACON

6.3 Installation in VACON

6.4 Installation in VACON

6.5 Installation in VACON

6.6 VACON

PC tools.............................................................................................................37

6.6.1 PC tool support ................................................................................................................37

6.6.2 OPTE2/E8 option board firmware update with VACON® Loader....................................37

6.6.3 PC tools for VACON

6.6.4 PC tools for VACON

7. Commissioning ..............................................................................................45

7.1 Option board menu...........................................................................................................45

7.1.1 Option board monitor menu.............................................................................................45

7.1.2 Option board parameter menu ........................................................................................46

7.1.3 System Parameter menu.................................................................................................47

8. Modbus RTU ...................................................................................................48

8.1 Overview ...........................................................................................................................48

8.2 Modbus RTU communications.........................................................................................48

8.2.1 Data addresses in Modbus message...............................................................................48

8.2.2 Modbus memory map ......................................................................................................48

8.2.3 Modbus exception responses ..........................................................................................49

8.3 Modbus data mapping......................................................................................................49

8.3.1 Holding and input registers .............................................................................................49

8.4 Quick setup.......................................................................................................................59

8.5 Example messages ..........................................................................................................60

20 X and 20 CP ...........................................................................25

100 family ..................................................................................28

100 X (enclosures MM4-MM6)...................................................31

NX...............................................................................................35

NXP/NXS: NCDrive .......................................................................40

100 family and VACON® 20: VACON® Live...................................42

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vacon • 4

8.5.1 Example 1: Write process data........................................................................................60

8.5.2 Example 2: Read process data ........................................................................................61

8.5.3 Example 3: Exception response.......................................................................................62

9. Metasys N2.....................................................................................................63

9.1 Overview ...........................................................................................................................63

9.2 Metasys N2 communication.............................................................................................63

9.2.1 Analogue Input (AI)...........................................................................................................63

9.2.2 Binary Input (BI) ...............................................................................................................63

9.2.3 Analogue Output (AO).......................................................................................................64

9.2.4 Binary Output (BO) ...........................................................................................................64

9.2.5 Internal Integer (ADI) .......................................................................................................64

9.3 Metasys N2 point map......................................................................................................65

9.3.1 Analogue Input (AI)...........................................................................................................65

9.3.2 Binary Input (BI) ...............................................................................................................65

9.3.3 Analogue Output (AO).......................................................................................................67

9.3.4 Binary Output (BO) ...........................................................................................................67

9.3.5 Internal Integer (ADI) .......................................................................................................68

9.4 Quick setup.......................................................................................................................69

10. Appendix A - Fieldbus parametrization..........................................................70

10.1 Fieldbus control and basic reference selection ..............................................................70

10.2 Controlling fieldbus parameter .......................................................................................71

10.3 Torque control parametrization ......................................................................................72

10.4 Response to fieldbus fault ...............................................................................................72

11. Appendix B - VACON® IO data description...................................................... 74

11.1 VACON® profile................................................................................................................74

11.1.1 VACON

11.2 Control Word bit support in VACON

11.3 VACON

11.4 Status Word bit support in VACON

11.5 Monitoring of control and status words in VACON

11.6 VACON

11.7 Process data.....................................................................................................................80

11.8 Fieldbus process data mapping and scaling ...................................................................80

11.8.1 Monitoring of process data in VACON

Control Word - FBFixedControlWord ...............................................................74

Status Word - FBFixedStatusWord ..................................................................77

speed reference and actual speed - FBSpeedReference and FBActualSpeed79

AC drives..............................................................76

AC drives ...............................................................78

AC drives ..........................................................82

AC drives.......................................78

12. Appendix C - Fieldbus option board communication ......................................84

12.1 Normal fieldbus communication .....................................................................................85

12.2 Normal Extended Mode ...................................................................................................86

12.3 Fast fieldbus communication ..........................................................................................87

12.4 Fast safety fieldbus communication................................................................................88

12.5 Fast PROFIBUS fieldbus communication ........................................................................89

13. Appendix D - Parameters for application developers ....................................91

14. Appendix E - Fault tracing..............................................................................93

14.1 Diagnostic information.....................................................................................................94

14.2 Typical fault conditions ....................................................................................................94

14.2.1 PLC master cannot get response from OPTE2/E8 RS485...............................................94

14.2.2 Data corruption in communication..................................................................................95

14.2.3 AC drive does not start to run..........................................................................................95

14.2.4 Drive runs with wrong speed ...........................................................................................96

14.2.5 AC drive reports Fieldbus timeout fault (F53).................................................................96

14.2.6 Fieldbus timeout fault (F53) cannot be reset ..................................................................96

14.3 Fieldbus timeout fault (F53).............................................................................................96

14.3.1 OPTE2/E8 RS485 fault conditions....................................................................................96

14.3.2 Fieldbus timeout fault (F53) diagnostic info....................................................................97

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Safety vacon • 5

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1. SAFETY

This manual contains clearly marked cautions and warnings that are intended for your personal safety and to avoid any unintentional damage to the product or connected appliances.

Read the information included in cautions and warnings carefully.

The cautions and warnings are marked as follows:

Table 1. Warning signs

= DANGER! Dangerous voltage

= WARNING or CAUTION

= Caution! Hot surface

1.1 Danger

The components of the power unit are live when the drive is connected to mains potential. Coming into contact with this voltage is extremely dangerous and may cause death or severe injury.

The motor terminals U, V, W and the brake resistor terminals are live when the AC drive is connected to mains, even if the motor is not running.

After disconnecting the AC drive from the mains, wait until the indicators on the keypad go out (if no keypad is attached, see the indicators on the cover). Wait 5 more minutes before doing any work on the connections of the drive. Do not open the cover before this time has expired. After expiration of this time, use a measuring equipment to absolutely ensure that no

ensure absence of voltage before starting any electrical work!

The control I/O-terminals are isolated from the mains potential. However, the relay outputs and other I/O-terminals may have a dangerous control voltage present even when the AC drive is disconnected from mains.

voltage is present.

Always

Before connecting the AC drive to mains make sure that the front and cable covers of the drive are closed.

During a ramp stop (see the Application Manual), the motor is still generating voltage to the drive. Therefore, do not touch the components of the AC drive before the motor has completely stopped. Wait until the indicators on the keypad go out (if no keypad is attached, see the indicators on the cover). Wait additional 5 minutes before starting any work on the drive.

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vacon • 6 Safety

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1.2 Warnings

The AC drive is meant for fixed installations only.

Do not perform any measurements when the AC drive is connected to the mains.

The earth leakage current of the AC drives exceeds 3.5mA AC. According to standard EN61800-5-1, a reinforced protective ground connection must be ensured. See Chapter 1.3.

If the AC drive is used as a part of a machine, the machine manufacturer is responsible for providing the machine with a supply disconnecting device (EN 60204-1).

Only spare parts delivered by VACON

can be used.

At power-up, power break or fault reset the motor will start immediately if the start signal is active, unless the pulse control for

Start/Stop logic has been selected Furthermore, the I/O functionalities (including start inputs) may change if parameters, applications or software are changed. Disconnect, therefore, the motor if an unexpected start can cause danger.

The motor starts automatically after automatic fault reset if the auto restart function is activated. See the Application Manual for more detailed information.

Prior to measurements on the motor or the motor cable, disconnect the motor cable from the AC drive.

Do not touch the components on the circuit boards. Static voltage discharge may damage the components.

Check that the EMC level of the AC drive corresponds to the requirements of your supply network.

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Safety vacon • 7

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1.3 Grounding and earth fault protection

CAUTION!

The AC drive must always be earthed with an grounding conductor connected to the grounding terminal marked with .

The earth leakage current of the drive exceeds 3.5mA AC. According to EN61800-5-1, one or more of the following conditions for the associated protective circuit must be satisfied:

a) The protective conductor must have a cross-sectional area of at least 10 mm

Al, through its total run.

b) Where the protective conductor has a cross-sectional area of less than 10 mm

Al, a second protective conductor of at least the same cross-sectional area must be

mm provided up to a point where the protective conductor has a cross-sectional area not less than 10 mm

Cu or 16 mm2 Al.

c) Automatic disconnection of the supply in case of loss of continuity of the protective

conductor.

Cu or 1 6 mm2

Cu or 16

The cross-sectional area of every protective grounding conductor which does not form part of the supply cable or cable enclosure must, in any case, be not less than:

-2.5mm

-4mm

if mechanical protection is provided or

if mechanical protection is not provided.

The earth fault protection inside the AC drive protects only the drive itself against earth faults in the motor or the motor cable. It is not intended for personal safety.

Due to the high capacitive currents present in the AC drive, fault current protective switches may not function properly.

Do not perform any voltage withstand tests on any part of the AC drive. There is a certain procedure according to which the tests must be performed. Ignoring this procedure can cause damage to the product.

NOTE! You can download the English and French product manuals with applicable safety, warning and caution information from https://www.danfoss.com/en/service-and-support/.

REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l’ensemble des informations de sécurité, avertissements et mises en garde applicables sur le site https://www.danfoss.com/en/service-and-support/.

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vacon • 8 General

2. GENERAL

OPTE2/E8 RS-485 multiple protocols field option board supports both Modbus RTU and Metasys N2 protocols. With these fieldbuses, the AC drives can then be controlled and monitored from the master.

OPTE2/E8 RS485 can be installed to the following VACON

•VACON® 20

•VACON

20 X / CP

100 INDUSTRIAL

FLOW

HVAC

100 X

NXP

NXS

AC drives:

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Option board technical data vacon • 9

3. OPTION BOARD TECHNICAL DATA

3.1 General

Table 2. Technical da ta

Protocols Modbus RTU / Metasys N2

Interface

Data transfer

Communications

method Transfer cable Shielded Twisted Pair Electrical isolation 500 VDC Ambient operating

temperature Storing temperature -40°C–70°C

Environment

Humidity <95%, no condensation allowed Altitude Max. 1,000 m Vibration 0.5 G at 9–200 Hz

Safety Fulfills EN50178 standard

OPTE2: 5-pin pluggable connector OPTE8: 9-pin D-SUB connector (female)

RS-485, half-duplex

-10°C–50°C

3.2 New features

• Support for VACON® NXP and VACON® NXS AC drives. See control firmware requirements in Chapter 6 "Installation".

• Support for 16 Modbus RTU process data items in VACON

NXP, VACON drives. See details in Chapter 8.3 "Modbus data mapping" and Chapter 12 "Appendix C - Fieldbus option board communication".

• Support for OPTC2/OPTC8 backward compatibility mode in VACON

"OPTC2/OPTC8 RS485 compatibility mode".

• Support for VACON® 100 INDUSTRIAL, VACON® 100 FLOW, VACON

drives.

•Initial version.

100 INDUSTRIAL and VACON® 100 FLOW AC

NX and VACON® 100 family AC drives. See Chapter

100 X, VACON® 100 HVAC and VACON® 20X/CP AC

Table 3. OPTE2/E8 RS485 firmware versions

New features Firmware version

V003

V002

V001

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vacon • 10 Layout and connections

4. LAYOUT AND CONNECTIONS

The difference between OPTE2 option board and OPTE8 option board is bus connector. OPTE2 option board has a 5-pin pluggable bus connector, and OPTE8 option board has a 9-pin female D-SUB connector. Except that, they have the same LED indications, jumpers and interface board connector.

4.1 OPTE2 (screw plug) option board layout

Figure 1. OPTE2 (screw plug) option board layout

Table 4. OPTE2 (screw plug) connector pinout

Signal Pin Description

Shield 1 Cable Shield VP 2 Supply voltage - plus (5V) RxD / TxD-P 3 Receive/Transmit data - plus(B) RxD / TxD-N 4 Receive/Transmit data - minus(A) DGND 5 Data ground (reference potential for VP)

NOTE! When replacing the OPTC2 option board with the OPTE2 option board, note that Receive/ Transmit data - plus (B) and Receive/Transmit data - minus (A) pins have switched places. In OPTC2, the pin 1 is not connected to the cable shield.

Table 5. OPTC2 (screw plug) connector pinout

Signal Pin Description

NC 1 No connection VP 2 Supply voltage - plus (5V) RxD / TxD-N 3 Receive/Transmit data - minus (A) RxD / TxD-P 4 Receive/Transmit data - plus (B)

DGND 5 Data ground (reference potential for VP)

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Layout and connections vacon • 11

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4.2 OPTE8 (Sub-D9) option board layout

Figure 2. OPTE8 (Sub-D9) option board layout

Figure 3. 9-pin female sub-D connector pinout

Table 6. OPTE8 (9-pin female sub-D) connector pinout

Signal Pin Description

Shield 1 Cable Shield VP 6 Supply voltage - plus (5V) RxD / TxD-P 3 Receive/Transmit data - plus (B) RxD / TxD-N 8 Receive/Transmit data - minus (A) DGND 5 Data ground (reference potential for VP)

NOTE! When replacing the OPTC8 option board with the OPTE8 option board, note that Receive/ Transmit data - plus (B) and Receive/Transmit data - minus (A) pins have switched places.

Table 7. OPTC8 (9-pin female sub-D) connector pinout

Signal Pin Description

Shield 1 Cable Shield VP 6 Supply voltage - plus (5V) RxD / TxD-N 3 Receive/Transmit data - minus (A) RxD / TxD-P 8 Receive/Transmit data - plus (B) DGND 5 Data ground (reference potential for VP)

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vacon • 12 Layout and connections

4.3 LED indications

There are three LEDs on OPTE2/E8 option board to indicate board and communication status. This table describes their indications.

Table 8. LED indications

LEDs Indication

• Green ON when protocol is communicating

Figure below lists possible LED indication combinations.

• Yellow blinking (1s ON / 1s OFF) when protocol is ready for external communication

• OFF when protocol is not ready for communications

• Green blinking (fast) when firmware is corrupted or missing

• Green ON when board is operational.

• Red blinking (1s ON / 1s OFF) when protocol is in fault state

• Green ON when protocol is communicating.

• OFF when protocol is not communicating.

Table 9. LED combinations

LED combinations

Description

PS BS FS

Dim Dim Dim No power. All LEDs are OFF

Green Dim Dim Option board firmware is corrupted or missing. PS is blinking fast

Dim

Yello w Green Dim Protocol is ready for communications. PS is blinking (1s ON / 1s OFF)

Green Green Green

Yello w Red Dim

Green Dim Option board is operational

Protocol is communicating. The option board is receiving requests from the PLC master and sending responses to the requests.

Protocol communication fault. BS is blinking to indicate a fault. PS is blinking to indicate that protocol is ready for communications.

4.4 Jumpers

Setting of termination resistance and cable shield grounding options is described in Chapter 5.

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Layout and connections vacon • 13

Bus termination ON

GND connected to cable shield

Jumper X13, termination resistor

Cable shield is connected to PE through RC

Cable shield is connected directly to PE

Cable shield is not connected

Bus termination OFF

GND not connected to cable shield

Jumper X14, upper row

Jumper X14, lower row

3022B_uk

Factory default setting

Figure 4. Position definition of jumpers

4.5 Bus terminal and bias resistors

If VACON® AC drive is the last device of RS-485 line, the bus termination must be set. Use jumper X13 (ON position) or external termination resistors.

Bus biasing is required to ensure faultless communication between devices at RS-485 bus. Bus biasing makes sure that the bus state is at proper potential when no device is transmitting. Without biasing, faulty messages can be detected when the bus is in idle state. RS-485 bus state should be neither +0.200...+7 V or -0.200...-7 V. Illegal bus state is <200 mV...-200 mV.

The resistance of internal termination and biasing are 120 Ω and 560 Ω.

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Figure 5. Bus termination

vacon • 14 Layout and connections

If necessary, external termination and biasing can be added depending on number of nodes and total length of cable.

Table 10. Bias resistance and termination resistance

Number of nodes Bias resistance Termination resistance

2-5 1.8 kΩ 5-10 2.7 kΩ 11-20 12 kΩ 21-30 18 kΩ 31-40 27 kΩ

120 Ω

Figure 6.

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Cabling instructions vacon • 15

5. CABLING INSTRUCTIONS

5.1 Selecting cable

In EIA-485 systems, use only shielded cables with twisted-pair signal wires. With EIA-485 protocols, use for example:

• Lapp Kabel UNITRONICR BUS LD FD P A, part number 2170813 or 2170814

5.2 Setting the termination resistance

Install termination resistors at or near both ends of the EIA-485 segment. The typically termination resistor for EIA-485 is 120 Ω.

A. The termination is activated D. The bus termination B. The termination is deactivated E. The fieldbus cable C. The termination is activated with a jumper

Figure 7. Setting the termination resistance

5.3 Shield grounding options

The equipotential bonding system in an installation refers to metalwork that is used to bring earth potential everywhere in the installation to a common level, the system earth. The purpose is that the earth potential for all devices and equipment would be same, avoiding undesirable current flow through paths not normally designed to carry current, and to allow efficient shielding of cables.

5.3.1 Shield grounding when equipotential bonding is good

When the equipotential bonding is good, the fieldbus cable shield can be grounded at each AC drive. The grounding can be done by connecting the shield to the drive frame directly, or it can be done through the fieldbus connector and the grounding tab in the option board.

Figure 8. Jumper X14 setting (all points in system)

If the fieldbus cable is subjected to tensile load, it is recommended to do this grounding via the fieldbus board connector and grounding tab. The strain relief of the cable is then done without exposing the cable shield, which reduces the risk of mechanical wear on the cable.

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vacon • 16 Cabling instructions

Figure 9. Grounding by clambing the cable to the AC drive frame

5.3.2 Shield grounding when equipotential bonding is poor

In a situation where the equipotential bonding is poor, the fieldbus cable should be grounded directly only at one point in the system. This can be a VACON the system. The fieldbus cable should not be directly grounded elsewhere in the system, because difference in electrical potential can cause equalization currents to appear in the shield, causing unnecessary disturbances.

Figure 10. Jumper X14 setting (cable grounding to drive)

Figure 11. Jumper X14 setting (cable shield to RC filter)

In VACON filter, which helps filter out disturbances in the shield without directly connecting it to the earth. In this case, the shield is connected to the option board connector and through an RC filter to the grounding tab in the option board. The strain relief is done without exposing the cable shield.

AC drives, the fieldbus cable can in these cases be connected to ground through an RC

AC drive but can also be some other point in

Figure 12. Grounding with RC filter

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Installation vacon • 17

6. INSTALLATION

Following table shows which drives support OPTE2/E8 option board.

Table 11. OPTE2/E8 option board support

VACON

Drive Slot

20 X/CP

100 INDUSTRIAL /100 X

100 FLOW

100 HVAC

NXP

NXS

Since drive software

version

E FW0107V013 FW0204V002

E FW00117V012 FW0204V002

D, E FW0072V026 FW0204V002

D, E FW0159V017 FW0204V002

D, E FW0065V035 FW0204V002

D, E NXP00002V197 FW0204V003

D, E NXS00002V184 FW0204V003

Since OPTE2/E8

software version

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vacon • 18 Installation

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6.1 Installation in VACON® 20

6.1.1 Enclosures MI1, MI2, MI3

Make sure power is disconnected before installing the option board mounting kit.

Remove the cable connector lid from AC drive.

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Select a correct grounding plate and attach it to the option board mounting frame. The grounding plate is marked with the supported enclosure size.

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Installation vacon • 19

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Attach an option board mounting frame to the AC drive.

Connect the flat cable from the option board mounting frame to the AC drive.

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If a cable strain relief is required, attach the parts as shown in the figure.

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vacon • 20 Installation

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Install the option board to the option board holder. Make sure that the option board is securely fastened.

Cut free a sufficiently wide opening for the option board connector.

Attach the option board cover to the AC drive. Attach the strain relief cable clamp with screws if needed.

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Installation vacon • 21

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6.1.2 Enclosures MI4, MI5

Make sure power is disconnected before opening the cover of the AC drive.

1a: For MI4: Open the cover.

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1b: For MI5: Open the cover and release the fan connector.

OPTE2: Attach the option board support.

OPTE8: Option board support is not used.

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vacon • 22 Installation

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Connect the flex cable to option board connector PCB.

Connect the option board to connector PCB.

Attach the option board with connector PCB to the AC drive and connect the flex cable.

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Installation vacon • 23

MI 04

MI 05

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Attach a suitable grounding plate to VACON® 20. The grounding plate is marked with supported enclosure size.

Assemble a clamp on top of the grounding plate on both sides of the option board.

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vacon • 24 Installation

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8a: For MI4: Close the cover.

8b: For MI5: Remount the fan connector and close the cover.

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Installation vacon • 25

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6.2 Installation in VACON® 20 X and 20 CP

Do not add or replace option boards or fieldbus boards on an AC drive with the power switched on. This may damage the boards.

Open the cover of the drive.

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MU3 example

The relay outputs and other I/O-terminals may have a dangerous control voltage present even when the drive is disconnected from mains.

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vacon • 26 Installation

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Remove the option slot cover.

Install the option board into the slot as shown in the figure.

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Installation vacon • 27

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Mount the option slot cover. Remove the plastic opening for the option board

terminals.

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vacon • 28 Installation

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DANGER

6.3 Installation in VACON® 100 family

Do not add or replace option boards or fieldbus boards on an AC drive with the power switched on. This may damage the boards.

Open the cover of the AC drive.

The relay outputs and other I/O-terminals may have a dangerous control voltage

present even when VACON

100 family AC drive is disconnected from mains.

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Installation vacon • 29

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Open the inner cover to reveal the option board slots (C,D,E). See the figure below.

Install the fieldbus board into slot D or E. See the figure below.

NOTE! Incompatible boards cannot be installed on VACON Compatible boards have a slot coding

that enable the placing of the board.

100 family AC drive.

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vacon • 30 Installation

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Fieldbus cables

Unless already done for the other control cables, cut free the opening on the AC drive cover for the fieldbus cable (protection class IP21).

NOTE! Cut the opening on the same side you have installed the board in

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Remount the AC drive cover and run the cable as shown in the figure.

NOTE! When planning the cable runs, remember to keep the distance between the fieldbus cable and the motor cable at a minimum of 30 cm. It is recommended to route the option board cables away from the power cables as shown in the figure.

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+ 69 hidden pages

Danfoss vacon, opte2, opte e8 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual

1. SAFETY

1.1 Danger

1.2 Warnings

1.3 Grounding and earth fault protection

2. GENERAL

3. OPTION BOARD TECHNICAL DATA

3.1 General

3.2 New features

4. LAYOUT AND CONNECTIONS

4.1 OPTE2 (screw plug) option board layout

4.2 OPTE8 (Sub-D9) option board layout

4.3 LED indications

4.4 Jumpers

4.5 Bus terminal and bias resistors

5. CABLING INSTRUCTIONS

5.1 Selecting cable

5.2 Setting the termination resistance

5.3 Shield grounding options

5.3.1 Shield grounding when equipotential bonding is good

5.3.2 Shield grounding when equipotential bonding is poor

6. INSTALLATION

6.1 Installation in VACON® 20

6.1.1 Enclosures MI1, MI2, MI3

6.1.2 Enclosures MI4, MI5

6.2 Installation in VACON® 20 X and 20 CP

6.3 Installation in VACON® 100 family