Leroy-Somer MD2 User Manual

User Guide

MD29

Microprocessor card and software for

Mentor II, Vector, CDE

and HPCDE Drives

Part Number: 0400-0030

Issue Number: 4

Safety Information

Persons supervising and performing the electrical installation or
maintenance of a Drive and/or an external Option Unit must be suitably
qualified and competent in these duties. They should be given the
opportunity to study and if necessary to discuss this User Guide before
work is started.

The voltages present in the Drive and external Option Units are capable of
inflicting a severe electric shock and may be lethal. The Stop function of
the Drive does not remove dangerous voltages from the terminals of the
Drive and external Option Unit. Mains supplies should be removed before
any servicing work is performed.

The installation instructions should be adhered to. Any questions or doubt
should be referred to the supplier of the equipment. It is the responsibility
of the owner or user to ensure that the installation of the Drive and
external Option Unit, and the way in which they are operated and
maintained complies with the requirements of the Health and Safety at
Work Act in the United Kingdom and applicable legislation and regulations
and codes of practice in the UK or elsewhere.

The Drive software may incorporate an optional Auto-start facility. In
order to prevent the risk of injury to personnel working on or near the
motor or its driven equipment and to prevent potential damage to
equipment, users and operators, all necessary precautions must be taken if
operating the Drive in this mode.

The Stop and Start inputs of the Drive should not be relied upon to ensure
safety of personnel. If a safety hazard could exist from unexpected
starting of the Drive, an interlock should be installed to prevent the motor
being inadvertently started.

General information

The manufacturer accepts no liability for any consequences resulting from
inappropriate, negligent or incorrect installation or adjustment of the
optional operating parameters of the equipment or from mismatching the
variable speed drive (Drive) with the motor.

The contents of this User Guide are believed to be correct at the time of
printing. In the interests of a commitment to a policy of continuous
development and improvement, the manufacturer reserves the right to
change the specification of the product or its performance, or the
contents of the User Guide, without notice.

All rights reserved. No parts of this User Guide may be reproduced or
transmitted in any form or by any means, electrical or mechanical including
photocopying, recording or by any information-storage or retrieval system,
without permission in writing from the publisher.

Copyright © November 1997 Control Techniques Drives Ltd
Author: CT SSPD
Originators AH, PB
Issue Code: 29nu4
Issue Date: November 1997
S/W Version: V2.6.0 system files and later.

Contents

1 Introduction 1-1

1.1 Overview 1-1

1.2 Memory 1-2

1.3 PC requirements 1-3

1.4 Technical data for the MD29 1-3

1.5 User knowledge 1-3

2 Installation 2-1

2.1 Installation procedure 2-1

2.2 Configuring the system 2-7

3 Getting Started 3-1

3.1 Introduction 3-1

3.2 Example DPL program 3-1

3.3 Creating a DPL file using the DPL Toolkit 3-5

4 DPL Programming 4-1

4.1 Program headers 4-1

4.2 Comments 4-3

4.3 Variables 4-3

4.4 Parameters 4-5

4.5 Operators 4-5

4.6 Tasks and real-time programming 4-7

4.7 Instructions and functions 4-13

4.8 Optimizing programs 4-15

4.9 Parameter pointers 4-17

4.10 Defining aliases (constants) 4-18

5 DPL Toolkit 5-1

5.1 Overview of the DPL Toolkit 5-1

5.2 File management 5-2

5.3 Editing a program 5-5

5.4 Applying styles 5-7

5.5 Compiling and running a program 5-8

5.6 Downloading a program 5-10

5.7 Running a program 5-11

5.8 Program monitoring and debugging facilities 5-11

6 Serial Communications 6-1

6.1 Introduction 6-1

6.2 Hardware connections 6-2

6.3 ANSI communications 6-4

6.4 Serial communications modes 6-13

6.5 ANSI instructions 6-16

6.6 Example ANSI instructions 6-16

7 Reference 7-1

7.1 Tasks 7-1

7.2 Instructions and functions 7-4

8 Features 8-1

8.1 Overview 8-1

8.2 PLC parameters 8-1

8.3 Introduction 8-2

8.4 Encoder lines 8-3

8.5 Position 8-3

8.6 Enabling the position controller 8-5

8.7 Default and Reset Values 8-6

8.8 Parameter descriptions 8-7

8.9 Logic diagrams 8-19

8.10 Using S-Ramps with Digital Lock 8-24

8.11 Cam function 8-25

8.12 Reference switching 8-28

8.13 Timer/Counter unit 8-30

8.14 Digital I/O ports 8-34

8.15 Non-volatile memory storage 8-35

8.16 Using the RS232 port for Drive to Drive
communications 8-35

9 Diagnostics 9-1

9.1 Run-time errors 9-1

9.2 Run-time trip codes 9-2

9.3 Compiler error messages 9-3

9.4 Advanced error-handling 9-5

10 Parameters 10-1

10.1 MD29 set-up parameters 10-1

10.2 Virtual parameters 10-4

10.3 RS485 port modes 10-10

10.4 General-purpose parameters 10-11

MD29
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Introduction 1-1

1 Introduction

On a Variable Speed Drive (such as Mentor II, Vector or CDE), timing
functions necessary for the correct operation of power devices are
performed by its own microprocessor operating in real-time. This imposes
limitations on the microprocessor when carrying out other duties, resulting
in a reduction of flexibility of the Drive.

To maximize this flexibility, a second processor can be used for running
application-specific software. This second microprocessor is the

MD29

which allows the Drive to be easily adapted to applications by programming
software in the MD29.

1.1 Overview

The MD29 is a compact microcomputer using surface-mount components on
a single printed circuit board. The board is designed for easy installation.

Together with the DPL Toolkit, the

MD29 allows the programmer to write

software or use pre-written software in order to enhance the flexibility of a
Variable Speed Drive.

The

MD29 is compatible with the following Drives:

• Mentor II, Vector, CDE, HPCDE

The MD29AN is a special version of the MD29. It has the full functionality of
the MD29 plus a CTNet interface for Mentor II Drives only. This interface
replaces the dedicated RS485 port for the Control Techniques I/O Box.

Note

The term MD29 in this manual also refers to the MD29AN,
unless specified otherwise.

The terms CDE750 and CDE7500 are used in this manual.
CDE750 refers to the bookcase CDE 0.75kW to 11kW range
(1

HP to 15HP); CDE7500 refers to the CDE 11kW to 90kW

range (7.5HP to 150HP), including the HPCDE.

MD29

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1-2 Introduction

DPL Toolkit (Windows™ interface)

The DPL Toolkit is contained on two diskettes. It is a program which runs in
Microsoft® Windows™ Version 3.1x and Windows™ 95. Programs for the
MD29 are written on a host PC using the DPL Toolkit.

Serial communications link

Host PC
(Desk-top or industrial)

The MD29 uses a high-level programming language called DPLDPL
(Drive Programming Language) which is in many respects similar to the
BASIC language. DPL is a compiled program which gives it the ability to run
at high speed.

The DPL Toolkit is used to write, compile and download a DPL program to an
MD29. The Toolkit also has a comprehensive set of de-bugging facilities to
aid the development and testing of the DPL program.

Connection between the MD29 and host PC is via an

RS232 serial

communications link. This link need only be used during program
development, testing and commissioning. It can be disconnected after the
software has been successfully loaded.

1.2 Memory

The compiled MD29 program and the user-created source program are
stored in non-volatile EEPROM memory on the MD29 card. This type of
memory allows the programs to be loaded using the serial port.

Latest versions of programs can be easily updated without removing any
integrated circuits or without using any specialized programming
equipment.

The filing system of the

MD29 allows only one program to be stored in the

MD29 at any one time.

The compiled program can be stored along with the DPL source code. This
allows the site engineer to read the program stored in the

MD29, even if the

program is not on the host PC. (This option can be disabled if it is not
required.)

MD29
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Introduction 1-3

1.3 PC requirements

The minimumminimum requirement for the DPL Toolkit is as follows:

IBM AT compatible 386SX PC, Windows™ 3.1, 4Mb RAM, DOS5

A 486

PC with 8MB RAM is recommended

1.4 Technical data for the MD29

Intel 960 32-bit RISC processor
96kb of user program storage
8kb user

RAM

16MHz clock

RS232 port for programming (IBM AT compatible)
RS485 optically isolated port for permanent serial communications

Dedicated, optically-isolated

RS485 port for a Control Techniques

I/O Box (not available on MD29AN)

1.5 User knowledge

This User Guide assumes that the user has at least superficial knowledge of
Microsoft® Windows™. Refer to the Windows User’s Guide for specific
information on performing operations in Windows™.

MD29

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1-4 Introduction

MD29
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Installation 2-1

2 Installation

Warning

The voltages present in the Drive are capable of inflicting a
severe electric shock and may be lethal. The Stop function
of the Drive does not remove dangerous voltages from the
Drive or the driven machine.

AC supplies to the Drive must be disconnected at least
15 minutes before any cover is removed or servicing work is
performed.

2.1 Installation procedure

Installation procedures are given for the following Drives:

Mentor II,

CDE7500/ HPCDE, Vector

Mentor II Drive

Mentor II

MD29

Location of the MD29 in the Mentor II DriveLocation of the MD29 in the Mentor II Drive

MD29

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2-2 Installation

Refer to the Mentor II User Guide for the mechanical details.
Use the following procedure to fit the

MD29 to the MDA2B circuit board of

the Drive:

1 Isolate the AC supply from the Drive.
2 Remove the front cover from the Drive.
3 Fit the four small securing pillars to the corners of the MD29.
4 Find the 40-pin header connector on the MDA2B circuit board of the

Drive.

Note

The following instruction requires you to fit the MD29 to
the Drive. Correct location of the header connector is
essential.

5 Fit the 40-pin connector of the MD29 on to the connector on the MDA2B

circuit board, ensuring the pins are aligned, and that the pillars on the

MDA2B circuit board are correctly aligned with the locating holes in the
MD29.

6 Push the MD29 carefully into position.
7 Check again that the 40-pin connector is correctly plugged in.
8 Fit the four securing pillars on each corner of the MD29 to the Drive

circuit board.

9 Make any necessary serial cable connections to the MD29.
10 Replace the Drive cover.

MD29
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Installation 2-3

CDE7500 and HPCDE Drives

Refer to the

CDE

User Guide for the mechanical details.

Use the following procedure to fit the

MD29 to the IN–82 control board in the

Drive, or to the IN-90 board in the HPCDE Drive:

1 Isolate the AC supply from the Drive.
2 Remove the front cover from the Drive.
3 Fit the four long pillars to the corner holes of the MD29.
4 Find the 40-pin header connector on the IN–82 control board in the

Drive.

MD29

IN-82

SMPS

Terminal Block

Location of the MD29 on the IN-82 card in the CDE7500Location of the MD29 on the IN-82 card in the CDE7500 Drive Drive

Note

The following instruction requires you to fit the MD29 to
the Drive. Correct location of the header connector is
essential.

MD29

Issue code: 29nu4

2-4 Installation

5 Fit the 40-pin connector of the MD29 on to the connector on the IN–82

control board, ensuring the pins are aligned, and that the pillars on the

IN–82 control board are correctly aligned with the locating holes in the
MD29.

6 Push the MD29 carefully into position.
7 Check again that the 40-pin connector is correctly plugged in.
8 Locate the four securing pillars on the corners of the MD29 to the IN–82

control board.

Note

The Drive cover cannot be re-fitted directly to the case.
The cover must be raised to allow room for the MD29 card.
Use the following procedure to fit the cover.

9 Fit the four hole-stud pillars (supplied with the MD29) to the corners of

the Drive.

10 Fit the pod extension connector (supplied with the MD29) to the

D-type connector of the control pod.

11 Make any necessary serial cable connections to the MD29.
12 Fit the cover on to the pillars.

MD29
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Installation 2-5

Vector Drive

IN-31

Terminal Block

MD29

Location of the MD29 on the IN-31 control board in the Vector DriveLocation of the MD29 on the IN-31 control board in the Vector Drive

Refer to the Vector User Guide for mechanical details.
Use the following procedure to fit the MD29 to the IN-31 control board in the

Drive:

1 Isolate the AC supply from the Drive.
2 Remove the front cover from the Drive.
3 Fit the four long pillars to the corner holes of the MD29.
4 Find the 40-pin header connector on the IN–31 control board in the

Drive.

Note

The following instruction requires you to fit the MD29 to
the Drive. Correct location of the header connector is
essential.

MD29

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2-6 Installation

5 Locate the 40-pin connector of the MD29 on to the connector on the

IN–31 control board, ensuring the pins are aligned, and that the pillars

on the

IN–31 control board are correctly aligned with the locating holes

in the

MD29.

6 Push the MD29 carefully into position.
7 Check again that the 40-pin connector is correctly plugged in.
8 Fit the four securing pillars on the corners of the MD29 to the IN–31

control board.

Note

The Drive cover cannot be re-fitted directly to the case.
The cover must be raised to allow room for the MD29 card.
Use the following procedure to fit the cover.

9 Fit the four hole-stud pillars (supplied with the MD29) to the corners of

the Drive.

10 Fit the pod extension connector (supplied with the MD29) to the D-

type connector of the control pod.

11 Make any necessary serial cable connections to the MD29.
12 Fit the cover on to the pillars.

Bookcase CDE

It is recommended that fitting of the MD29 to bookcase Drives is carried out
by an authorized distributor since internal access to the Drive is required.

MD29
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Installation 2-7

2.2 Configuring the system

Host PC connections

RS232 Port

The

RS232 serial port is a dedicated link to the host PC. The port is a 9-way

female D-type connector. Ready-made cables for RS232 serial
communications are generally available.

The table below gives the minimum required connections between the

MD29

and a 9-way and 25-way pin COM port connector.

MD29

pin no.

9-pin connector

pin no.

25-pin connector

pin no.

22 3
33 2
55 7

The RS232 port should be used only for commissioning because isolation or
protection of the port is not included.

Use the following instructions for connecting a host

PC:

1 Ensure no static charge has built up when the plug is inserted.
2 Using a maximum cable length of not more than 3 metres (10 feet),

connect an

RS232 cable to the RS232 serial port on the MD29 and to the

communications serial port of the host

PC.

Installing the DPL Toolkit in the host PC

Use either of the following procedures:

Windows 3.1

The DPL Toolkit requires a minimum of 4Mb of computer memory. This may be

RAM or

virtual memory. Virtual memory may be set in the 386386 Enhanced Enhanced section of Windows
Control Panel.

1 Start Microsoft Windows
2 Insert disk 1 of the DPL Toolkit into the A: drive of the host PC.
3 In Windows Program Manager, select FileFile on the menu bar. Select RunRun.
4 Type A:\SETUP.

5 Click on

MD29

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2-8 Installation

Windows 95

1 Insert disk 1 of the DPL Toolkit into the A:A: drive of the host PC.

2 In the menu, select RRun...un....

3 Type A: \SETUP .

4 Click on

Downloading the system file

The MD29 has no pre-loaded system software. The first task is to program
the system software using the DPL Toolkit. Use the following procedure:

1 Connect the serial communications cable to the MD29.
2 Apply AC power to the Drive.
3 In Windows 3.xx Program Manager, or in the Windows 95 Start menu,

click on:

The DPLDPL Toolkit Toolkit window appears. At the top of the window are a

menu bar and toolbar.

4 If the serial port of the host PC is not COM1, open the ProjectsProjects menu

and select ConfigureConfigure. In the drop-down menu that appears, select
ComportComport. This opens a further drop-down menu which allows
selection of the required communications port.

5 Click on (Open Task ManagerOpen Task Manager). After a few moments, the DPLDPL

Task ManagerTask Manager dialog box appears.

MD29
Issue code: 29nu4

Installation 2-9

If the dialog box does not appear, and all the buttons in the lower

toolbar of the window appear shaded (inactive), communications
could not be established with the

MD29. Check the connecting cable is

correct, and the correct

COM port is used.

6 Click on . The File Viewer File Viewer dialog box appears.

In the panels on the left side of the dialog box the path and names of

the

.SYS files can be selected.

Note

The system files are located in directory MD29GUI\BIN\SYS.

7 Select the correct path for the required system files. Double-click on

the .

SYS file specified in the following table:

Drive File

Mentor II M2.SYS
Mentor II (MD29AN) M2NET.SYS
Vector VECT.SYS
CDE (bookcase) CDES.SYS
CDE and HPCDE CDEL.SYS

MD29

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2-10 Installation

Note

The system files for MD29 issue 1 are located in directory
MD29GUI\BIN\SYS\MD29ISS1.

The ProgrammerProgrammer dialog box appears.

8 Click on (green light showing). The system file is now loaded

into the

MD29.

MD29
Issue code: 29nu4

Getting Started 3-1

3 Getting Started

3.1 Introduction

This chapter explains the key elements of DPL programming, and the
methods used to create, compile and run an example program using the DPL
Toolkit.

An example of a short

DPL program is given below, followed by explanations

of the program instructions.

3.2 Example DPL program

The DPL program described here is called SawtoothSawtooth, because it applies a
repetitive cycle consisting of a linear increase in speed demand followed by
an instantaneous reduction to zero, as shown in the following diagram.

Repetitve cycle produced by the Repetitve cycle produced by the SawtoothSawtooth program program

MD29

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3-2 Getting Started

Start

#1.18 = 0

Is #1.18 < 1000?

#1.18=#1.18+1

Yes

No

Flow diagram of program Flow diagram of program SawtoothSawtooth

Program instructions

$TITLE Sawtooth
$VERSION 1.1.1
$DRIVE Mentor
$AUTHO R MyName
$COMPA NY MyCo
//Note: T his is a c o mm e nt.

BACKGROUND{

Top:
#1.18=0

DO WHI LE #1.18<1000

#1.18=#1.18+1

LOOP
GOTO

Top:

}

MD29
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Getting Started 3-3

Explanation of the example program

$TITLE Sawtooth

The first line of a program must be

$TITLE program name. The name

can have a maximum of 64 characters.

$VERSION 1.1.1

The second line is

$VERSIO N number. The number can have a maximum

of eight characters. The recommended format is $VERSI ON 1.0.0.
Updates are easily shown by increasing the last number, eg. 1.0.11.0.1.

Major modifications are shown by 2.0.02.0.0, 3.00 3.00, etc.

$DRIVE Mentor

The third line is

$DRIVE drive name. This tells the compiler which Drive

it is installed in. (Since the DPL Toolkit can be used with different
types of Drive, the name of the Drive must be stated.) The list of
suffixes are as follows:

•

MENTOR

• CDE750 (bookcase CDE)

• CDE7500 (large CDE and HPCDE)

• VECTOR

$AUTHOR MyName
$COMPANY MyCo

The fourth and fifth lines are used to define the author of the program
and the company name.

Note

Unless these lines are included, the program will not be
compiled.

//Note: This is a comment.

The program ignores comment lines which can be placed anywhere in a
program. Comments are always preceded by either a double forward
slash [////] or a semi colon[;].

Comments are useful for inserting descriptions, or for giving
explanations for the benefit of the user or programmer.

BACKGROUND{

BACKGROUND is a type of Task. (All executable code must be

contained within a Task.) There are many different types of Task,
which, in effect, define the priority of the code and allow blocks of
code to be run on different time-bases.

The

BACKGROU N D task is a free-running task which can be compared to

the way a PLC runs a program, for example. Full details of the Tasks are
given in Real-time programming in Chapter 4 DPL Programming.

MD29

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3-4 Getting Started

Top:

Top:Top: is a label which marks an absolute position in the program. A label
must always be followed by a colon [::].

A label defines the destination of a

GOTO statement. It can be given

any name (eg. mylabelmylabel).

#1.18=0

A hash (##) expression accesses Drive parameters. In this case the
parameter is 1.18 (menu 1, parameter 18). This is a preset speed
reference parameter in the Mentor Drive, and it is set at zero.

DO WHILE #1.18<1000

DO WHILE is a loop statement. In this example, it gives the program an

instruction to repeat the following block of code while the value of
parameter 1.18 is less than 1000.

#1.18=#1.18+1

This line adds the value 11 to parameter 1.18. Every time this command is
executed, 11 is added to the parameter value.

LOOP

LOOP is the end expression for the Instruction DO WHILE. LOOP tells

the program to go back to the line DO WHILE and check that the DO

WHILE

instruction remains true. When the value of #1.18 = 10001.18 = 1000, DO

WHILE

#1.18 < 1000 #1.18 < 1000 becomes false. The instructions between DO

WHILE

and LOOP stop being repeated and the program goes to the

next line after the LOOP command.

GOTO Top:

GOTO is a flow-control instruction. In this case, it tells the program to

go to the label Top:Top:. This causes the program to run continuously.

Note

The label name must be specified using a colon[:].

} Closing brace

Instructions within braces belong to the defined Task. Closing-braces
work in conjunction with opening-braces. In this example, the
opening- and closing-braces work in conjunction with the Task

BACKGROUND..

MD29
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Getting Started 3-5

3.3 Creating a DPL file using
the DPL Toolkit

This section shows how to write, compile and download the example
DPL program for the Mentor II Drive.

Opening the DPL Toolkit

In Windows 3.xx Program Manager, or Windows 95 Start menu, click on:

The DPLDPL Toolkit Toolkit window appears. At the top of the window are a menu bar
and toolbar.

Creating a file

1 Click on or open the File File menu and select NewNew.
2 Enter the following program exactly as it appears, using the tab key to

indent lines.

$TITLE Sawtooth
$VERSION 1.1.1
$DRIVE mentor
$AUTHO R MyName
$COMPA NY MyCo
//Note: T his is a c o mm e nt.

BACKGROUND{

Top:
#1.18=0

DO WHI LE #1.18<1000

#1.18=#1.18+1

LOOP
GOTO

Top:

}

MD29

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3-6 Getting Started

3 Open the FileFile menu and select Save As...Save As.... The Save File AsSave File As dialog box

appears.

4 In the Folders: Folders: list, select the ProjectsProjects directory. In the FileFile name: name:

text box, type

SAWTOOTH.DPL.

5 Click on . The file is now saved.

The program is ready for compiling into machine code.

Important Note

DPL programs must be saved as .DPL files. If this is not

done, the program cannot be compiled into machine code.
Only the saved version of the program is compiled.

Compiling the program

The DPL Toolkit contains a compiler which converts DPL programs from text
format to binary machine code which the MD29 can understand. The
compiler converts the .DPL file into a binary file with a .BIN extension.

Use the following procedure.

1 Click on at the right of the Toolbar. The Compile...Compile... dialog box

appears.

MD29
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Getting Started 3-7

2 If the DPL source file is required to be downloaded to the MD29, ensure

the Embed DPL Source CodeEmbed DPL Source Code check box is checked. This facility
allows the DPL program to be read back to the

PC at a later date (if the

computer copy becomes lost, for example).

If the DPL source file is not to be downloaded, ensure the check box is

unchecked. When the Compile...Compile... dialog box next appears, the check
box retains the last setting.

(The other options in this dialog box are described in Compiling and

running programs in Chapter 5 DPL Toolkit.)

3 Click on
4 The CompilationCompilation box appears for a few seconds. It is not necessary to

observe the contents of the CompilationCompilation box.

5 The program is now compiled, ready for downloading to the MD29.

If instead a Build errorsBuild errors window appears with errors displayed, correct

the program for typing mistakes and repeat the compilation. (Error
messages are described in Chapter 9, Diagnostics.)

MD29

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3-8 Getting Started

Connecting to the MD29

It is now necessary to establish communications from the host PC to the

MD29 in order to download the compiled file.

Use the following procedure:

Click on

. The Task Manager opens with the Task Manager toolbar

appearing below the standard toolbar.

Note

If all the buttons on the lower toolbar appear shaded, it is
an indication that communications could not be
established with the MD29. Check that AC power is applied
to the Drive, and that the serial communications cable is
correctly inserted.

Downloading the program

1 In the Task Manager toolbar, click on . The ProgrammerProgrammer dialog

box appears.

MD29
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Getting Started 3-9

2 In the ProgrammerProgrammer dialog box, click on (green light showing).

The files

SAWTOOTH..BIN and SAWTOOTH.. DPL are now downloaded to

the

MD29. Down-loading takes a few seconds to complete.

Note

The MD29 can hold only one compiled program (ie. .BIN file)
in memory at one time. A program that is downloaded to
the MD29 will over-write an existing program.

Running the program

Warning

The Sawtooth program rapidly alters the speed reference
parameter of the Drive. For safety, ensure the Drive is
disabled before running the program.

In the Task Manager toolbar, click on
The Speed referenceSpeed reference parameter #1.18 #1.18 in the Drive will change value.

Note that the ramping-up behavior cannot be observed since the
program alters the parameter value at a faster rate than the display is
updated.

MD29

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3-10 Getting Started