Danfoss vacon 100 industrial, vacon 100 flow, vacon 100 hvac, vacon 100 x User guide

®

vacon 100 industrial

vacon 100 flow

®

vacon 100 hvac

®

vacon 100 x

®

ac drives

modbus tcp/udp and modbus rtu

user manual

vacon • 1

Table of Contents

Document: DPD00156D

Version release date: 30.11.16

1. Safety................................................................................................................3

1.1 Danger.................................................................................................................................3

1.2 Warnings .............................................................................................................................4

1.3 Earthing and earth fault protection ....................................................................................5

2. Modbus - general info.......................................................................................6

3. Modbus technical data ......................................................................................8

3.1 Modbus RTU protocol .........................................................................................................8

3.2 Modbus TCP protocol..........................................................................................................8

3.3 Modbus UDP vs TCP............................................................................................................8

3.4 Connections and wiring ....................................................................................................11

3.5 ACD (Address Conflict Detection) in Ethernet network ...................................................11

4. Installation......................................................................................................12

4.1 Installation in VACON® 100 family AC drives ..................................................................12

4.1.1 Prepare for use through ethernet ....................................................................................13

4.1.2 Prepare for use through RS485........................................................................................15

4.2 Installation in VACON® 100 X...........................................................................................19

4.2.1 Prepare for use through Ethernet....................................................................................19

4.2.2 Prepare for use through RS485........................................................................................20

5. Fiedlbus parametrization ...............................................................................22

5.1 Fieldbus control and basic reference selection...............................................................22

5.1.1 Torque control parametrization .......................................................................................22

5.1.2 Enabling Modbus protocol ................................................................................................23

5.2 Modbus RTU parameters and monitoring values (M5.8.3) ..............................................23

5.2.1 Slave address ....................................................................................................................24

5.2.2 Baud rate...........................................................................................................................24

5.2.3 Parity type .........................................................................................................................24

5.2.4 Stop bits.............................................................................................................................24

5.2.5 Communication timeout ...................................................................................................24

5.2.6 Operate mode....................................................................................................................24

5.2.7 IDMap IDs ..........................................................................................................................25

5.2.8 Fieldbus protocol status ...................................................................................................25

5.2.9 Communication status......................................................................................................25

5.2.10Illegal functions ................................................................................................................26

5.2.11Illegal data addresses ......................................................................................................26

5.2.12Illegal data values.............................................................................................................26

5.2.13Slave device busy ..............................................................................................................26

5.2.14Memory parity error .........................................................................................................26

5.2.15Slave device failure...........................................................................................................26

5.2.16Last fault response...........................................................................................................26

5.2.17Control word .....................................................................................................................26

5.2.18Status word .......................................................................................................................26

5.3 Modbus TCP/UDP parameters and monitoring values ....................................................27

5.3.1 Ethernet common settings (M5.9.1) .................................................................................27

5.3.2 IP Address mode ...............................................................................................................27

5.3.3 Fixed IP address................................................................................................................27

5.3.4 Fixed Subnet Mask............................................................................................................28

5.3.5 Fixed default gateway .......................................................................................................28

5.3.6 Active IP address, subnet mask and default gateway......................................................28

5.3.7 MAC Address.....................................................................................................................28

5.3.8 Modbus TCP/UDP settings (M5.9.2)..................................................................................28

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vacon • 2

5.3.9 Connection limit ................................................................................................................29

5.3.10Unit Identifier number ......................................................................................................29

5.3.11Communication timeout ...................................................................................................29

5.3.12IDMap IDs..........................................................................................................................29

6. Communications .............................................................................................30

6.1 Data addresses in Modbus messages ..............................................................................30

6.2 Supported Modbus Functions...........................................................................................30

6.3 Modbus data mapping.......................................................................................................31

6.3.1 Coils registers...................................................................................................................31

6.3.2 Clearing resettable counters............................................................................................31

6.3.3 Discrete inputs ..................................................................................................................31

6.3.4 Holding registers and input registers ..............................................................................32

6.3.5 Vacon Application IDs........................................................................................................33

6.3.6 FB Process data IN ...........................................................................................................33

6.3.7 FB Process data OUT ........................................................................................................34

6.3.8 ID map ...............................................................................................................................35

6.3.9 Operation day counter.......................................................................................................36

6.3.10Resettable operation day counter ....................................................................................37

6.3.11Energy counter..................................................................................................................38

6.3.12Resettable energy counter ...............................................................................................39

6.3.13Fault history ......................................................................................................................40

6.3.14Fault history with 16-bit error codes................................................................................40

6.4 Modbus TCP/UDP communication and connection timeout............................................41

6.5 Example messages ...........................................................................................................42

6.5.1 Example 1 - Write Process Data.......................................................................................42

6.5.2 Example 2 - Read process data ........................................................................................43

6.5.3 Example 3 - Exception response ......................................................................................44

7. Fault tracing ...................................................................................................45

7.1 Typical fault conditions .....................................................................................................45

7.2 RS-485 bus biasing ...........................................................................................................45

7.3 Other fault conditions .......................................................................................................46

8. Quick setup .....................................................................................................48

9. APPENDIX 1 - PROCESS DATA ........................................................................49

10. APPENDIX 2 - CONTROL AND STATUS WORD ................................................. 50

10.1 Control Word bit description ......................................................................................50

10.2 Status Word Descriptions ...........................................................................................52

11. APPENDIX 6 - LWIP LICENCE..........................................................................53

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Safety vacon • 3

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1. SAFETY

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

Please 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

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 ensure

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.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

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vacon • 4 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 stan-
dard 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
Futhermore, 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.

.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

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Safety vacon • 5

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1.3 Earthing and earth fault protection

CAUTION!

The AC drive must always be earthed with an earthing conductor connected to the earthing 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 shall be satisfied:

b) The protective conductor shall have a cross-sectional area of at least 10 mm2 Cu or 16

mm2 Al, through its total run.

c) Where the protective conductor has a cross-sectional area of less than 10 mm2 Cu or 16

mm2 Al, a second protective conductor of at least the same cross-sectional area shall be
provided up to a point where the protective conductor has a cross-sectional area not less
than 10 mm2 Cu or 16 mm2 Al.

d) Automatic disconnection of the supply in case of loss of continuity of the protective conduc-

tor.

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

-2.5mm

-4mm

2

if mechanical protection is provided or

2

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 shall be performed. Ignoring this
procedure may result in damaged product.

NOTE! You can download the English and French product manuals with applicable safety,
warning and caution information from

http://drives.danfoss.com/knowledge-center/technical-documentation/.

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 http://drives.danfoss.com/knowledge-center/technical-documentation/
.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

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vacon • 6 Modbus - general info

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Master´s

message

Slave

response

Start

Address

Function

Data

CRC

End

Start

Address

Function

Data

CRC

End

2. MODBUS - GENERAL INFO

Modbus is a communication protocol developed by Modicon systems. In simple terms, it is a way of
sending information between electronic devices. The device requesting the information is called the
Modbus Master (or the Client in Modbus TCP/UDP) and the devices supplying information are Mod­bus Slaves (in Modbus TCP/UDP servers). The Master can also write information to the Slaves. Mod­bus is typically used to transmit signals from instrumentation and control devices back to a main
controller or data gathering system.

Standard Modbus network contains one Master device and up to 247 Slave devices. In ModbusRTU
and ModbusUDP networks it is mandatory to define a unique Slave Address (or Unit identifier num­ber) for the every Slave Device. Slave Address is a number between 1 and 247. In ModbusTCP net­works, it is not mandatory to define a unique Slave Address, because the IP address identifies the
device.

The Modbus communication interface is built around messages. The format of these Modbus mes­sages is independent of the type of physical interface used. The same protocol can be used regard­less of the connection type. Because of this, Modbus gives the possibility to easily upgrade the
hardware structure of an industrial network, without the need for large changes in the software. A
device can also communicate with several Modbus nodes at once, even if they are connected with
different interface types, without the need to use a different protocol for every connection.

2

Figure 1.Basic structure of Modbus frame

On simple interfaces like RS485, the Modbus messages are sent in plain form over the network. In
this case the network is dedicated to Modbus. When using more versatile network systems like
TCP/IP over Ethernet, the Modbus messages are embedded in packets with the format necessary
for the physical interface. In that case Modbus and other types of connections can co-exist at the
same physical interface at the same time. Although the main Modbus message structure is peer­to-peer, Modbus is able to function on both point-to-point and multidrop networks.

Each Modbus message has the same structure. Four basic elements are present in each message.
The sequence of these elements is the same for all messages, to make it easy to parse the content
of the Modbus message. A conversation is always started by a master in the Modbus network. A
Modbus master sends a message and—depending of the contents of the message—a slave takes
action and responds to it. There can be more masters in a Modbus network. Addressing in the mes­sage header is used to define which device should respond to a message. All other nodes on the
Modbus network ignore the message if the address field does not match their own address.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Modbus - general info vacon • 7

Your VACON® 100 family AC drive is equipped with Modbus support as standard. If you need to con-

®

tact VACON
with the Drive Info File taken with VACON

service in problems related to Modbus, send a description of the problem together

®

Live to customer support. If possible, also send a "Wire-

shark" log from the situation if applicable.

Ethernet

Modbus TCP

Switch

Modbus
RTU
master

Modbus RTU

Figure 2.Principal example diagram of Modbus

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vacon • 8 Modbus technical data

3. MODBUS TECHNICAL DATA

3.1 Modbus RTU protocol

Table 2.

Interface RS-485
Data transfer method RS-485 MS/TP, half-duplex

STP (Shielded Twisted Pair), type Belden
9841 or similar

2.5 mm

As described in “Modicon Modbus Proto­col Reference Guide”
300, 600, 1200, 2400, 4800, 9600, 19200,
38400, 57600, 76800, 115200 and 230400
bits/s

2

Connections and
communications

Transfer cable

Connector
Electrical isolation Functional

Modbus RTU

Bitrate

Addresses 1 to 247

3.2 Modbus TCP protocol

Table 3.

Interface 100BaseTX, IEEE 802.3 compatible
Data transfer method Ethernet half/full -duplex
Data transfer speed 10/100 MBit/s, autosensing

Connections and
communications

Protocol Modbus TCP
Connector Shielded RJ45 connector
Cable type CAT5e STP

Modbus TCP

Default IP Selectable: Fixed or DHCP (AutoIP)

As described in Modbus Messaging
Implementation Guide

3.3 Modbus UDP vs TCP

In addition to TCP, the VACON® 100 family AC drive supports also UDP starting from following firm­ware versions:

®

•VACON

•VACON

•VACON

It is recommended that UDP is used when reading and writing rapidly and repetitively (cyclically)
the same data as in case of process data. TCP must be used for single operations, like service data
(e.g. reading or writing parameter values).

100 INDUSTRIAL and VACON® 100 X: FW0072V025

®

100 FLOW: FW0159V016

®

100 HVAC: FW0065V035

3

The key difference between UDP and TCP is that when using TCP, each and every Modbus frame
needs to be acknowledged by the receiver (see the figure below). This adds extra traffic to the net­work and more load to the system (PLC and drives) because software needs to keep track of sent
frames to make sure that they have reached their destination.

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Modbus technical data vacon • 9

Modbus TCP Communication

PLC

TCP, SYN

TCP, SYN, ACK

Open

Connection

Modbus Response, TCP, ACK

Communicate

Close

Connection

TCP, ACK

Modbus Query

TCP, ACK

Modbus Query

TCP, ACK
TCP, ACK

TCP, FIN, ACK

TCP, ACK

Drive

Modbus UDP Communication

PLC Drive

Modbus Query

Modbus Response

Modbus Query

Communicate

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Figure 3. Modbus TCP and UDP communication comparison

Another difference between TCP and UDP is that UDP is connectionless. TCP connections are al­ways opened with TCP SYN messages and closed with TCP FIN or TCP RST. With UDP, the first
packet is already a Modbus query. IP address and port combination is treated as a connection. If
port number changes, it is considered as a new connection or as a second connection if both stay
active.

When using UDP, it is not guaranteed that the sent frame reaches its destination. The PLC must
keep track of the Modbus requests by using the Modbus transaction id-field. It actually must do this
also when using TCP. If the PLC does not receive response in time from the AC drive in UDP con­nection, it needs to send the query again. When using TCP, the TCP/IP stack will keep resending the
request until it has been acknowledged by the receiver (see Figure 4). If the PLC sends new queries
during this time, some of those may not be sent to the network (by TCP/IP stack) until previous sent
package(s) has been acknowledged. This can cause small packet storms when the connection is re­sumed between the PLC and the AC drive (See Figure 5).

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3

vacon • 10 Modbus technical data

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Modbus TCP Communication

PLC Drive

Modbus Query (1)

Modbus Query (2)

Modbus Response (1), TCP, ACK

Modbus Response (2), TCP, ACK

TCP, ACK

TCP retransmission, Modbus Query (2)

TCP retransmission, Modbus Query (2)

Normal communication continues

Packet lost, no response

Packet lost, no response

Modbus Query (1)

Modbus Response (1)

Modbus Response (4)

Modbus Query (2)

Modbus Query (3)

Modbus Query (4)

Packet lost, no response

Packet lost, no response

Normal communication continues

Modbus UDP Communication

PLC Drive

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Modbus TCP Communication

PLC Drive

Modbus Modbus

TCP

stack

TCP

stack

Modbus Query (1)

Modbus Query (2)

Modbus Query (3)

Modbus Query (4)

Modbus Query

(1,2,3)

Modbus Query (4)

Modbus Response

(1,2,3)

Modbus Response

(4)

TCP Modbus Query

TCP, ACK

TCP, ACK

TCP, ACK

TCP, ACK

TCP, Modbus Response (1,2,3)

TCP, Modbus Response (4)

TCP, Modbus Query (4)

Retransmission

Modbus Query (1,2,3)

Retransmission Modbus Query (1,2,3)

Retransmission

Modbus Query (1,2)

Retransmission

Modbus Query (1)

Modbus

Response (1,2,3)

Modbus

Response (4)

Normal communication continues

Packet lost

Figure 4. Modbus TCP and UDP communication errors comparison

Figure 5. Modbus TCP retransmissions

3

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Modbus technical data vacon • 11

Losing one packet is not a big issue because the same request can be sent again after timeout. In
TCP, the packages always reach their destination but if network congestion causes retransmis­sions, the resent packages will most likely contain old data or instructions when they reach their
destination.

3.4 Connections and wiring

The VACON® 100 family AC drive supports 10/100Mb speeds in both Full- and Half-duplex modes.
However, real-time process control requires the Full-duplex mode and the 100-megabit speed.
Drives must be connected to the Ethernet network with a Shielded Twisted Pair (STP) CAT-5e cable
(or better). Use only industrial standard components in the network and avoid complex structures
to minimize the length of response time and the amount of incorrect dispatches.

The maximum length of an RS-485 cable depends on the bitrate used, the cable (gauge, capacitance
or characteristic impedance) and the number of devices in the bus. The Modbus RTU specification
states that for a maximum 9600 bits/second bitrate and AWG26 or wider gauge, the maximum
length is 1000 meters. The actual cable length used in an installation can be lower than this number
depending on the aforementioned parameters.

3.5 ACD (Address Conflict Detection) in Ethernet network

The VACON® 100 family AC drive implements the ACD algorithm (IETF RFC 5227).

The ACD algorithm tries to actively detect if the IP address configured to this device is used by an­other device in the same network. To accomplish this, the ACD sends four ARP request packets
when the device's Ethernet interface goes up or when its IP address changes. The ACD prevents the
use of the Ethernet interface until the ARP probing finishes. This delays the startup of fieldbus pro­tocols about one second. During the delay or after it, the ACD passively checks incoming ARP mes­sages for use of the device's IP address. If another device with the same IP address is detected, the
ACD will try to defend its IP address with a single ARP message. If the other device with the same
IP address also supports ACD, it should stop using the address. If not, the ACD will close the Ether­net connection and indicate the situation with an Alarm. This is done according the "DefendWith­PolicyB". Acknowledging of the Alarm is not possible if the problem is active. The ACD opens an
Ethernet connection if the other device with the same IP address disappears from the network. The
alarm can be acknowledged after this. Other policies are not supported. If the fieldbus protocol has
been active, a fieldbus fault may be activated (depends on the fieldbus and drive application config­uration).

The ACD functionality can be enabled and disabled with Duplicate IP Detection panel parameter
(see Chapter 5.3.1 Ethernet common settings (M5.9.1)).

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

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vacon • 12 Installation

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4. INSTALLATION

4.1 Installation in VACON® 100 family AC drives

Open the cover of the AC drive.

1

2

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

Open the inner cover of the drive.

4

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Installation vacon • 13

Ethernet
cable

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4.1.1 Prepare for use through ethernet

Connect the Ethernet cable (see specification in Chapter 3.2) to its terminal as
shown in figure below.

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Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

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vacon • 14 Installation

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IP54

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IP21

Ethernet
cable

Protection class IP21: Cut free the opening on the AC drive cover for the Ether­net cable.
Protection class IP54: Cut the rubber grommets open to slide the cables
through. Should the grommets fold in while inserting the cable, just draw the
cable back a bit to straighten the grommets up. Do not cut the grommet open­ings wider than what is necessary for the cables you are using.
NOTE! To meet the requirements of the enclosure class IP54, the connection
between the grommet and the cable must be tight. Therefore, lead the first bit of
the cable out of the grommet straight before letting it bend. If this is not possi­ble, the tightness of the connection must be ensured with insulation tape or a
cable tie.

4

5

Remount the AC drive cover.
NOTE! When planning the cable runs, remember to keep the distance between
the Ethernet cable and the motor cable at a minimum of 30 cm. See figure below.

4

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Installation vacon • 15

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1

5

m

m

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4.1.2 Prepare for use through RS485

Strip about 15 mm of the RS485 cable (see specification in Chapter 3.1) and cut
off the grey cable shield. Remember to do this for both bus cables (except for the
last device).
Leave no more than 10 mm of the cable outside the terminal block and strip the
cables at about 5 mm to fit in the terminals. See picture below.

Also strip the cable now at such a distance from the terminal that you can fix it to

1

the frame with the grounding clamp. Strip the cable at a maximum length of 15
mm. Do not strip the aluminum cable shield!

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