Danfoss X5MBTCP01 Installation guide

X5MBTCP01 Modbus TCP Option Board

with 115 VAC Encoder Interface

Installation Manual

DPD00112

Need Help?

This manual answers most installation and startup questions

that may arise. However, if you have any problems,

please let your first call be to us.

Vacon, Inc.

Chambersburg, PA 17202

Normal business hours:

(North America)

8:00 AM to 5:00 PM, Eastern time

+1 877-Vacon06

([phone])

After-hours support is also available

and Vacon, Inc. are trademarks of Vacon Plc, a member of Vacon Group.

All other product names are trademarks of their respective companies.

Copyright 2009, Vacon, Incorporated. All rights reserved.

X5MBTCP01 Modbus TCP with 115 VAC / Encoder Interface Option Board vacon  3

Installing the X5MBTCP01 Modbus TCP Option Board
with 115 VAC Encoder Interface

Introduction

The X5 frequency converters can be connected to Modbus TCP using a Modbus TCP option board, the X5MBTCP01.

Every device connected to a Modbus / TCP network has two identifiers: a MAC address and an IP address. The MAC
address (formatted as xx:xx:xx:xx:xx:xx, where xx is a hexadecimal byte) is unique to the device and cannot be
changed. The Modbus / TCP board’s MAC address can be found on the sticker attached to the board or by using
various network configuration tools.

In a local network, IP addresses can be defined by a user as long as all units connected to the network are given the
same network portion of the address. For more information about IP addresses, contact your Network
Administrator. Overlapping IP addresses cause conflicts between devices.

The X5MBTCP01 also provides the option of controlling the X5 AC drive from 115 VAC control signals, or of
connecting a shaft-mounted encoder to the drive to improve speed regulation. Up to five channels of 115 VAC control
are available for use in selecting direction, preset speeds, or other drive functions.

With this option, an encoder with a nominal rating of up to 2048 pulses per revolution can be connected to the X5
unit to improve speed load regulation of the drive. Overall encoder frequency at maximum process speed must be
limited to 100kHz.

This option also provides two additional control relays, each rated for 115 VAC, 1 amp, or for 230 VAC, 0.5 amp.

NOTE: This network communication interface included with the X5 option is warranted
to meet the core specifications for Modbus TCP. Many existing software applications are
custom-engineered and may contain “brand-specific” communication that will not be
supported by the X5 without modification. No guarantee of compatibility with any
specific system is made. The user is responsible for any interface software and
hardware needed to make an application function.

Applicable Documents

This manual is supplied as a supplement to the X5 AC Drive User’s Manual (DPD 00089, previously Form 1434).

Option Kit Contents

The option kit includes the following materials:

Part Number Description

25100104C Modbus / TCP Option Board

32100391 Flexible cable assembly

Installation Procedures

SENSITIVE EQUIPMENT

This assembly contains static-sensitive components. It should be handled only by a static-safe installer,
using a grounded wrist strap.

Failure to observe this precaution may cause premature equipment failure.

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!

WARNING

4  vacon X5MBTCP01 Modbus TCP with 115 VAC / Encoder Interface Option Board

!

DANGER

HAZARDOUS VOLTAGE

• Disconnect all power before servicing a drive unit or its components. WAIT 5 MINUTES until the DC
bus capacitors discharge.

• Ensure that any other power sources that may feed control logic have been disconnected.

• DO NOT short across DC bus capacitors or touch unshielded components or terminal strip screw
connections with voltage present.

• Install all covers before applying power or starting and stopping the drive.

• The user is responsible for conforming to all applicable code requirements with respect to grounding
all equipment.

• Many parts in a drive, including printed circuit boards, operate at line voltage. DO NOT TOUCH. Use
only electrically-insulated tools.

Before servicing any drive.

• Disconnect all power.

• Place a “DO NOT TURN ON” label on the drive disconnect.

• Lock the disconnect in the open position.

Failure to observe these precautions will cause shock or burn, resulting in severe personal injury
or death.

Figure 1 shows the option board and the location of the terminals and the power supply selector.

Encoder / 115 VAC Interface

Control Relay Terminals

Encoder Interface Power

Supply Selector

Modbus / TCP Connector

Module Status LED

Figure 1: Option Board Layout

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Network Status LED

X5MBTCP01 Modbus TCP with 115 VAC / Encoder Interface Option Board vacon  5

Before you can install the option board, you must first remove the drive cover.

Figure 2 shows the locations of the cover screws. The torque range for the X5 Size 1 cover is 18-26 in/lbs.

Cover screw locations

Figure 2: Cover Assembly and Screw Locations

Cover screw locations

The option board is installed just above the control board in all configurations (a Size 1 unit is shown in Figure 3 for
reference). The screws labeled “A” must be removed from the X5; those labeled “B” need only to be loosened to
accept the board slot.

.

B

A

B

A

Figure 3: Option Mounting Locations

Once the board is in place, tighten the screws to a maximum of 26 in-lbs.

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6  vacon X5MBTCP01 Modbus TCP with 115 VAC / Encoder Interface Option Board

Next, install the flexible circuit to finish the interface to the control board. (Refer to Figure 4.) To install the flexible
circuit, first remove the keypad frame (necessary in this size unit). The frame is attached with two screws in opposite
corners; the screws thread into fasteners in the plastic assembly. After the flexible circuit is installed, replace these
screws, limiting the installation torque to 12 in-lbs..

Figure 4: Flexible Circuit Interface to Control Board

115 VAC Interface / Relay / Encoder Interface Terminals

Figure 5: 115 VAC Interface / Encoder Terminals

The X5OPT01 option kit includes five 115 VAC inputs, two additional programmable relays, and an encoder interface.
The details of the terminals on the board related to the 115 VAC interface and the encoder are shown in Table 1 on
page 7:

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X5MBTCP01 Modbus TCP with 115 VAC / Encoder Interface Option Board vacon  7

Table 1: Encoder Interface Terminals

Terminal Description

DI-A
DI-B
DI-C
DI-D
DI-E

ACn The neutral connection for the 115 VAC control inputs

NO3

RC3
NC3

NO4

RC4
NC4

A+
A-

B+
B-

C+
C-

VDC

Ecom Signal common for the encoder interface

115 VAC logic input; connect input to 115 VAC to activate.
The programmable functionality of these inputs is controlled by

parameters 728, 729, 730, 731, and 732. Each of these inputs can be
disabled or configured to emulate the function of the FWD, REV, R/J, EN,
MOL, DI1, DI2, DI3, DI4, or DI5 input terminals on the X5 control board.

Refer to the X5 User’s Manual for more information (DPD 00089).

The third auxiliary relay.
The function of this relay is set by parameter 709. Functionally, it is

capable of each of the features outlined in the X5 user manual under
parameters 705-708.

Terminal NO3 is a normally-open contact; it closes when the relay
activates. NC3 is a normally-closed contact; it opens when the relay
activates. RC3 is the common terminal associated with both contacts.

The ratings of these contacts are 115 VAC, 1 amp; and 230 VAC, 0.5 amp.

The fourth auxiliary relay.
The function of this relay is set by parameter 710. Functionally, it is

capable of each of the features outlined in the X5 user manual under
parameters 705-708.

Terminal NO4 is a normally-open contact; it closes when the relay
activates. NC4 is a normally-closed contact; it opens when the relay
activates. RC4 is the common terminal associated with both contacts.

The ratings of these contacts are 115 VAC, 1 amp; and 230 VAC, 0.5 amp.

Channel A input from the encoder. Compatible with line driver, open
collector, or totem pole outputs from an encoder. If it is an open
collector or totem pole-type, encoder outputs are used; connect the A­terminal to Ecom.

Channel B input from the encoder. Compatible with line driver, open
collector, or totem pole outputs from an encoder. If it is an open
collector or totem pole-type, encoder outputs are used; connect the B­terminal to Ecom.

Channel C input from the encoder, the home pulse. Compatible with line
driver, open collector, or totem pole outputs from an encoder. If it is an
open collector or totem pole-type, encoder outputs are used; connect
the C- terminal to Ecom.

Power supply terminal for use with a customer-supplied encoder. It can
be either +12 VDC or +5 VDC based on the position of the encoder
interface power supply selector shown in Figure 1. Voltage regulation:
+/- 5%; maximum current available is 100 mA.

Note that the connections described in Table 1 work only when the encoder has an internal pull-up resistor on the
open collector. Alternatively, it might be preferable to pull the + channel high, and attach the open collector to the ­channel. For example, if using Channel A, A+ on the option board would be tied to VDC, and A- would be connected
to the open collector coming from the encoder. The advantage in this method is that no pull-up/down resistors are
needed; if the encoder has an internal pull-up, this does not affect anything.

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8  vacon X5MBTCP01 Modbus TCP with 115 VAC / Encoder Interface Option Board

Specifications for Encoder / 115 VAC Interface

Encoder Interface 115 VAC Interface

Speed regulation < 0.1 Hz (1) On state 90-140 VAC

Input frequency (max.) 100 kHz Off state < 10 VAC

Input voltage 10-24 VDC +/- 5% Input frequency 58-62 Hz

Suggested pull-up

resistor

Terminal block wire

limitations

(1) PID feedback plus optimal motor turning in SLV mode employed

5 VDC 500 ohms

24 VDC 3.3k ohms

12-24 AWG

On/off delay 30 ms maximum12 VDC 1k ohms

Terminal block wire
limitations

12-24 AWG

Setup and Use

The encoder interface is most effective if used in conjunction with the vector mode of operation. Refer to the X5
User’s Manual (Chapter 6) for information about using the vector mode. Three additional parameters are provided
to calibrate the encoder:

Parameter # Parameter Name Range Default Value

219 Encoder Pulses per Revolution 0-16383 1024

220 Encoder Filter Time 10-1000 ms 20 ms

221 Encoder Speed Protection 0-20.0% 0%

Parameter 219, Encoder Pulses per Revolution, can either be extracted from the encoder nameplate or the data
sheet supplied with it. Parameter 220, Encoder Filter Time, is used to filter the encoder signal in the event of noise.
Parameter 221 is for limiting the response of the drive, in the event of the loss of encoder signal.

Two other parameters are provided to allow more flexibility in encoder selection, and to improve PID application
usage:

Parameter # Parameter Name Range Default Value

Quadrature

223 EncoderType

224 Encoder Range 0-24000 rpm 0 rpm

or Single
Channel

Quadrature

Parameter 223, Encoder Type, allows the use of either quadrature or single-channel types of encoders.

Parameter 224, Encoder Range, improves PID application flexibility. This parameter should be used in situations
where the encoder feedback signal is not always directly proportional to the motor speed, for example, a winder
using an encoder mounted on an idler pulley feeding a winding spool. The PID may be attempting to maintain a
constant linear speed on the wound media, but as the diameter of the media on the spool changes, the motor turning
the spool needs to vary its speed to maintain the linear speed at the idler pulley.

When parameter 224 is set to 0, it is ignored, and the PID calculates the feedback percentage based on parameter
301, Maximum Frequency. When this parameter is set to a non-zero value, the PID uses instead Parameter 224’s
setting to calculate the feedback percentage.

Encoder feedback works similarly to an analog input as configured in parameters 850 (PID Configure), 851 (PID
Feedback), 852 (PID Prop Gain), 853 (PID Int Gain), and 859 (PID Derivative Gain). The “feed forward” options are
suggested for setting parameter 850. More specific details on each of the listed parameters can be found in the X5
User’s Manual (DPD 00089).

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X5MBTCP01 Modbus TCP with 115 VAC / Encoder Interface Option Board vacon  9

The encoder interface can easily serve as one of the inputs to the X5’s Keeper Function (data logging). See the X5
User’s Manual for more information.

Both the Vmet and Imet output from the drive can be configured to indicate the status of the encoder. Parameters
700 (Vmet) and 702 (Imet) that relate to the setup and calibration of the Vmet and Imet outputs, both have selections
related to the status of the encoder input.

The Program Sequencer function can also key off the encoder’s home pulse. To make use of this function, the
encoder’s home pulse (1 pulse per revolution) must be connected to the C- input of the encoder board.

Troubleshooting

Any problem with the encoder interface will result in an F37 fault. Four advanced fault codes are available to help
you determine whether you have an encoder calibration problem, or a defect. For more information on
troubleshooting, refer to the Troubleshooting chapter in the X5 User’s Manual.

Using Modbus / TCP

Following are the specifications for Modbus / TCP connections:

Table 2: Modbus / TCP Connection Specifications

Connections Interface RJ-45 Connector

Transfer cable Foiled CAT5e

Speed 10 / 100 Mb

Communications

Duplex half/full

Default IP address 0.0.0.0

Sub-net mask 255.255.255.0

To communicate with the drive over Modbus / TCP, the drive’s IP address must be set. This is done with parameters
922-925. After setting the IP address, be sure to cycle power off and back on for the new address to take effect.

LED Indications

The Modbus / TCP Option Board includes two LED status indicators: Network Status and Module Status. See Figure

1 on page 4 for the location of these LEDs on the board. Network status provides information on the network

connection status and Module status provides information on the Modbus / TCP module itself. The following tables
explain the meaning of the status LEDs:

Table 3: Network Status LED

Network Status

LED

If the LED is... This means...

OFF There is no power applied to the option board.

Red The Modbus / TCP option cannot communicate on the network.

Table 4: Module Status LED

If the LED is... This means...

OFF There is no power applied to the option board.

Green The option board is operating normally.

Module Status

LED

Green (flashing)

Red (flashing) The option board has detected a recoverable fault.

Red The option board has detected an unrecoverable fault.

The option board is in Standby state or the device needs
commissioning because of a missing, incomplete, or incorrect
configuration.

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10  vacon X5MBTCP01 Modbus TCP with 115 VAC / Encoder Interface Option Board

Getting Started

To begin communicating with the drive over Modbus / TCP, the drive’s IP address must be set (use parameters 922-

925). After setting the IP address, cycle power off and on for the new address to take effect.

For information on setting parameters, see the X5 User’s Manual.

Modbus / TCP is a variant of the Modbus family. It is a manufacturer-independent protocol for monitoring and
controlling automatic devices. Modbus / TCP is a client server protocol. The client makes queries to the server by
sending request messages to the server’s TCP port 502. The server answers client queries with a response
message. The term “client” can refer to a master device that runs queries. Correspondingly, the term “server”
refers to a slave device that serves the master device by answering its queries. Both the request and the response
messages are composed as follows:

Byte Content

0 Transaction ID

1 Transaction ID

2 Protocol ID

3 Protocol ID

4 Length field upper byte

5 Length field upper byte

6 Unit identifier

7 Modbus function code

8 Data (of variable length)

Modbus / TCP vs. Modbus / RTU

Compared to the Modbus / RTU protocol, Modbus / TCP differs mostly in error checking and slave addresses. As
TCP already includes an efficient error-checking function, the Modbus / TCP protocol does not include a separate
CRC field. In addition to error checking functionality, TCP is responsible for re-sendiing packets and for splitting
long messages so that they fit the TCP frames. The slave address field of the Modbus / RTU is named as the unit
identifier field in Modbus / TCP, and it is only used when one IP address stands for several endpoints.

Modbus / TCP Option Board’s Modbus Addresses

Currently, the X5 only implements Modbus holding registers (addresses 40001 - 4FFFF). The Modbus / TCP option
board supports the same register ranges and function codes that are available through the drive’s serial port via
Modbus RTU. For more information, see Chapter 7 of the X5 User’s Manual.

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X5MBTCP01 Modbus TCP with 115 VAC / Encoder Interface Option Board vacon  11

Modbus / TCP Troubleshooting

Following are the advanced fault codes for the drive fault (F38) related to the option board. For more information,
see the X5 User’s Manual (Chapter 8). The option board status LEDs are described on page 9 of this manual.

Table 5: Advanced Fault Codes

Advanced

Fault Code

1 Option board loss

2 Unstable ID during power-up Option board hardware issues

3 Option board changed

4 Invalid ID Option board hardware issues

5

6 Option board software Option board software issues

7 Option board removed

Wrong or no daughter card
installed

Fault Possible Cause Corrective Measures

Option board is disconnected or
damaged

Option board was changed during
last power-down

Option DIMM module issues

Option board was removed during
last power-down sequence

Following are Modbus / TCP Exception Responses:

Table 6: Exception Responses

Check option board status LEDs,
ribbon cable connection, and
cycle power. Replace option
board if necessary.

Cycle power. If problem persists,
contact Vacon technical support.

If the change was intentional,
cycle power.

Cycle power. If problem persists,
contact Vacon technical support.

Cycle power. If problem persists,
contact Vacon technical support.

Cycle power. If problem persists,
contact Vacon technical support.

If the change was intentional,
cycle power. Otherwise, follow
corrective measures for fault
code 1.

Error Response Name Meaning

The function code received in the query is not an allowable

1 Illegal Function

2 Illegal Data Address

3 Illegal Data Value

4 Slave Device Failure

5 Acknowledge

6 Slave Device Busy

action for the slave. For example, this error would be
returned when attempting to write (preset) a read-only
register.

The data address received in the query is not a valid address
in the slave.

A value contained in the query data field is not an allowable
value for the slave register (that is, above the parameter’s
maximum or below the minimum).

An unrecoverable error occurred while the slave was
attempting to perform the requested action.

The Modbus / TCP option board is having trouble
communicating with the X5 control board.

The slave cannot process the request at this time. The
master should re-transmit the message later when the
slave is available. This usually only occurs when two
masters simultaneously query a slave, or the polling rate
from the master is too fast for the slave.

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production:

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