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BU2200
User Manual
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NORD BU2200 User Manual

GB
BU 2200
POWERLINK Bus module
Supplementary manual options for NORD - Frequency Inverters
POWERLINK Bus module – Supplementary manual options for NORD - Frequency Inverters
Name:
BU 2200
Part No.:
608 22 02
Series:
POWERLINK Bus System
Name previous versions
Software Version
Remarks
BU 2200 GB, September 2013 Part No. 608 22 02 / 3813
V. 1.2 R0
First edition, including addition of BU 0580
NOTICE
Supplementary operating manual
This supplementary operating manual is only valid in conjunction with the operating manual supplied for the respective frequency inverter. This is an essential prerequisite for the availability of all the relevant information required for the safe commissioning of the frequency inverter.
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Documentation
Version list
Table 1: Version list
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Publisher
Getriebebau NORD GmbH & Co. KG
Getriebebau-Nord-Straße 1 22941 Bargteheide, Germany http://www.nord.com/ Fon +49 (0) 45 32 / 289-0 Fax +49 (0) 45 32 / 289-2555
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=== Ende der Liste für Textmarke Copyrig ht ===
Table of Contents
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Table of Contents
=== Ende der Liste für Textmarke Inhalts verzeichnis ===
1. Introduction ................................................................................................................................................. 6
1.1 General .............................................................................................................................................. 6
1.2 Bus modules ...................................................................................................................................... 6
2. Bus Configuration ....................................................................................................................................... 7
2.1 Topology ............................................................................................................................................ 7
2.2 Cable layout and shielding (EMC measures) ..................................................................................... 7
3. Configuration in the Bus System ............................................................................................................... 8
3.1 Addressing ................................................................ ......................................................................... 8
3.2 Integration into the bus master ........................................................................................................... 9
3.3 Remote Maintenance (in preparation) .............................................................................................. 10
3.4 Configuration example ..................................................................................................................... 10
4. Communication and Protocol .................................................................................................................. 12
4.1 NMT State Machine ......................................................................................................................... 12
4.2 Processing of Process Data in the Frequency Inverter .................................................................... 13
4.2.1 Control word (STW) ............................................................................................................ 14
4.2.2 Status word (ZSW) ............................................................................................................. 14
4.2.3 Frequency inverter status machine ..................................................................................... 16
4.2.4 Setpoint (SW) and Actual Value (IW) ................................................................................. 18
4.2.5 Example: "Switch on and off + setpoint" ............................................................................. 19
4.3 Transfer of process data .................................................................................................................. 19
4.4 Parameter transfer ........................................................................................................................... 21
5. Parameter ................................................................................................................................................... 24
5.1 Bus - Module Parameters ................................................................................................................ 24
5.2 Frequency Inverter Parameters ....................................................................................................... 30
6. Error monitoring and error messages ..................................................................................................... 32
6.1 Bus operation monitoring function .................................................................................................... 32
6.2 Resetting error messages ................................................................................................................ 33
6.3 Handling of errors in the bus module ............................................................................................... 33
6.3.1 Error monitoring via the frequency inverter ......................................................................... 33
6.3.2 Error monitoring via POWERLINK ...................................................................................... 34
7. Additional information .............................................................................................................................. 37
7.1 Repair information ............................................................................................................................ 37
7.1.1 Repairs ............................................................................................................................... 37
7.1.2 Internet information ............................................................................................................. 37
7.2 Further Documentation and Software .............................................................................................. 38
POWERLINK Bus module – Supplementary manual options for NORD - Frequency Inverters
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List of illustrations
=== Ende der Liste für Textmarke Abbildung sverzeichnis ===
Fig. 1: Installation and cable laying information ....................................................................................................... 7
Figure 2: NMT State Machine ................................................................................................ ................................ 12
Fig. 3: Status Machine of the Frequency Inverter .................................................................................................. 17
List of tables
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List of tables
=== Ende der Liste für Textmarke Tabelle nverzeichnis ===
Table 1: Version list ................................................................................................................................................. 2
Table 2: Hardware Overview ................................................................................................................................... 6
Table 3: POWERLINK node ID assignment ............................................................................................................ 8
Table 4: Configuration example - Devices used .................................................................................................... 10
Table 5: Explanation of the NMT State Machine ................................................................................................... 13
Table 6: Control word (STW) ................................................................................................................................. 14
Table 7: Status word (ZSW) .................................................................................................................................. 15
Table 8: Depiction of 32Bit setpoint/actual values ................................................................................................. 18
Table 9: Example: "Switch FI on and off + setpoint" .............................................................................................. 19
Table 10: PDO Mapping / Process Data Structure SK TU3-POL .......................................................................... 20
Table 11: PDO Mapping / Process Data Structure SK XU4-POL .......................................................................... 21
Table 12: Structure of the Input Word in the Process Data ................................................................................... 21
Table 13: Structure of the Output Word in the Process Data ................................................................................. 21
Table 14: Device Assignment to SDO-ID .............................................................................................................. 21
Table 15: Sub-Index Coding .................................................................................................................................. 22
Table 16: Error codes for parameter access failure ............................................................................................... 23
Table 17: Overview of Frequency Inverter Parameters ......................................................................................... 31
Table 18: Error Entry Structure .............................................................................................................................. 34
Table 19: Error groups according to communication profile DS-301 ..................................................................... 34
Table 20: Assignment of BUS errors to inverter errors .......................................................................................... 36
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1 Introduction
Name
Part. No.
Remarks
Document
SK CU4-POL
275 271 018
for frequency inverters SK 180E … SK 2xxE (internal)
TI 275271018
SK TU3-POL
275 900 150
for NORD frequency inverters SK 5xxE
TI 275900140
SK TU4-POL
275 281 119
for frequency inverters SK 180E … SK 2xxE (IP55)
TI 275281118
plus:
SK TI4-TU-BUS
275 280 000
Bus connection unit (IP 55)
TI 275280000
SK TU4-POL-C
275 281 169
for frequency inverters SK 180E … SK 2xxE (IP66)
TI 275281168
plus:
SK TI4-TU-BUS-C
275 280 500
Bus connection unit (IP 66)
TI 275280500
1
1. Introduction
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1.1 General
Modern field bus systems, microcontrollers and communication networks have had a great influence on automation systems and have resulted in greater flexibility, availability, and ultimately, a reduction in costs.
The widespread use of PC-based control only became possible with the availability of field bus systems. With increasing control unit performance, the classic field bus ultimately became the limiting criterion for the entire system. It was therefore an obvious step to adapt Ethernet technology, which provides high rates of data transmission in IT applications, to the field of automation.
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The bus system
POWERLINK is an industrial Ethernet solution, which was designed for the unified and consistent integration of all communications relating to modern automation. It is suitable for all conceivable applications in mechanical and plant engineering, as well as for applications in the processing industry. A POWERLINK network integrates all components for industrial automation, such as PLCs, sensors, I/O modules, motion controllers, safety controls, safety sensors and actuators, as well as visualisation systems. As not only process data are transferred in a POWERKINK cycle, but rather in its asynchronous phase a firmly reserved time slot is available for the transfer of any type of user data such as data which is not time-critical, e.g. service data for remote maintenance or configuration of devices. Likewise, devices can be integrated into the network, which do not directly belong to the automation level, for example video cameras for the safety control of operating areas. With a suitable gateway, data from other field buses can be transferred via the asynchronous phase, so that different networks can be integrated.1
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1.2 Bus modules
Specific bus modules are available as interfaces between the field bus system and the NORD system bus or the NORD frequency inverter. A document exists for each module (Technical Information / Data Sheet), which includes the technical data, as well as installation and configuration information (www.nord.com).
Table 2: Hardware Overview
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EPSG: POWERLINK Basics, MM-D00843.713, 2008
POWERLINK Bus module – Supplementary manual options for NORD - Frequency Inverters
Fixed cable
Freely laid cable
Bending radius of cable
Minimum radius 5 x cable diameter
Minimum radius 10 x cable diameter
Correct
Incorrect
NOTICE
Potential equalisation
If earthing potential values are different, transient current may flow through shielding which is connected on both sides. This may be a danger to electronic components. Differences in potential must be reduced by means of adequate potential equalisation.
2. Bus Configuration
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2.1 Topology
Up to 239 NORD bus modules can be integrated into an POWERLINK network. The network can be configured as a star or tree topology, as a linear bus, or a mixture of these variants. Hubs or switches are necessary if star or tree structures are used. These must comply with the special requirements of POWERLINK. The length of cable between two neighbouring devices must not exceed 100m.
Detailed information about the bus modules is contained in the relevant Technical Information / Data Sheets.
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2.2 Cable layout and shielding (EMC measures)
If EMC measures are not in place, high-frequency interference which is mainly caused by switching processes or lightning often causes electronic components in the bus subscribers to be faulty and error-free operation can no longer be ensured.
Appropriate shielding of the bus cable reduces electrical interference which can arise in an industrial environment.
The best shielding qualities can be achieved with the following measures:
• Do not make cable connections shorter than 1 m between bus participants
• Avoid long connections between bus participants
• Shield the bus cable at both ends with large-area connection to the plug housing
• Avoid spur lines
• Avoid extensions to bus cables via plug connectors
Bus lines should be laid with a minimum spacing of 20 cm to other lines which carry a voltage higher than 60 V. This applies to lines laid inside and outside of control cabinets.
Special attention should be paid to bending radii:
Fig. 1: Installation and cable laying information
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3 Configuration in the Bus System
1.
IP address via module parameter
Perform the addressing via module parameter P160. The DIP switch for the IP address on the relevant module must be set to "0" (default value).
2.
IP address via DIP switch
The last byte of the IP address can be set via the DIP switches on the module. (refer to the Technical Information or Data Sheet for the module ( LINK))
Information
Adoption of the address
All settings to the parameters P160 ... P165 and the DIP switches are only adopted after a bootup (restart of the module).
POWERLINK Node ID
Description
Access options
0
C_ADR_INVALID
Invalid
no
1 … 239
Regular POWERLINK CNs
no / mandatory / optional / isochronous / async only
240
C_ADR_MN_DEF_NODE_ID
POWERLINK MN
mandatory isochronous
241 … 250
Reserved Used by EPSG DS 302-A [1]
no
251
C_ADR_SELF_ADR_NODE_ID
POWERLINK pseudo node ID to be used by a node to address itself
no
252
C_ADR_DUMMY_NODE_ID
POWERLINK dummy node
no
253
C_ADR_DIAG_DEF_NODE_ID
Diagnostic device
optional
254
C_ADR_RT1_DEF_NODE_ID
POWERLINK to legacy Ethernet Router
no / mandatory / optional / isochronous
255
C_ADR_BROADCAST
POWERLINK broadcast
no
3. Configuration in the Bus System
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3.1 Addressing
The IP address and the SubNetMask are fixed.
– IP Address: 192.168.100.NodeID – SubNetMask: 255.255.255.0
The Gateway Address is parameterised (P164) to the standard value 192.168.100.254 and should not be changed.
The following alternative methods are available for the adjustment of the Node ID of the POWERLINK module (SK xUx-POL-…):
The resulting settings of the IP address and the sub-net mask can be read out in parameters P185 and P186.
POWERLINK stipulates strict ranges for the assignment of addresses
Table 3: POWERLINK node ID assignment
POWERLINK Bus module – Supplementary manual options for NORD - Frequency Inverters
Step
Action
1.
Import the XDD file into the PLC interface
2.
Integrate the bus module from the PLC database into the project (add POWERLINK control node).
3.
Assign the NODE ID (address) for the POWERLINK device
4.
Link process data to variables
Information
PLC Busmaster
By means of certification, NORD ensures that the bus system complies with the requirements which are made by the bus interfaces.
Various planning tools or control systems are commercially available. NORD assumes that the user who integrates the NORD bus module into the relevant control unit has the necessary knowledge of the bus system and is sufficiently familiar with the use of the planning tool or PLC.
Information
Readiness for operation
At the time of initialisation of the PLC, the frequency inverter or the bus module must be ready for operation. Otherwise, no data can be saved in the device via the module SK xUx-POL. The module responds to the PLC with an error. If the PLC module monitoring is enabled, the PLC then switches to Service Mode.
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3.2 Integration into the bus master
In order to be able to use the devices in the bus system they must be integrated into the PLC or the project.
The necessary device data for the bus devices are saved in the electronic device descriptions (XDD files). According to the module, various XDD files are available. These can be downloaded free of charge from www.nord.com.
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Module monitoring
The PLC continuously monitors the connection to the control node. If this interrupts communication, the PLC stops and then restarts the Service Mode.
Possible reasons for a communication breakdown are:
– The FI triggers an error and P163 is set to 1. – The BUS load is too high.
If the module monitoring is switched off, the PLC remains in RUN mode in case of a bus module error. No error entry is made in the PLC logger. However, the PLC attempts to restore communication with the module.
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Parameter initialisation
When the PLC is started, all of the available parameters can be automatically written. In addition, each object can be provided with an initial value. All of the parameters are written once when the PLC establishes communication with the Control Node.
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3 Configuration in the Bus System
ATTENTION
Remote control via NORDCON
For control via NORDCON it is important to set parameter P513 "Telegram timeout" according to the NORDCON cycle time. This ensures that the frequency inverter triggers an error if the Ethernet connection fails!
ATTENTION
Unauthorised access
Although the possibility of remote maintenance facilitates the control and analysis of the devices in case of faults, on the other hand it entails the danger of a "cyber attack" on the system.
The provision of suitable protection measures against unauthorised access is the responsibility of the constructor of the system. They are not the responsibility of Getriebebau NORD!
Serial No.
Frequency inverter type
Designation
1
SK 2x5E frequency inverter
FI 1
2
SK 2x5E frequency inverter
FI 2 3 SK 2x5E frequency inverter
FI 3 4 SK xU4-… (bus module)
Bus module
3.3 Remote Maintenance (in preparation)
With the aid of the NORDCON software it is possible to access the module and the underlying frequency inverter via Ethernet for maintenance purposes.
The access rights for remote maintenance are assigned with DIP switch and range from "read only parameter" (default) to "reading and writing access of parameters" and "remote control of the drive unit".
(For details, please refer to the "Technical Information / Data Sheet for the bus module).
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3.4 Configuration example
The example described below serves for orientation when commissioning a network consisting of a bus module and frequency inverters. The most important commissioning stages are listed, which are necessary to set up the exchange of data on the process data level.
Settings specific to the application (motor data, speed control, control terminal functions etc.) cannot of course be described here.
Brief description
Via a bus module, 3 frequency inverters are to be independently controlled with a single speed. The following devices are used:
Table 4: Configuration example - Devices used
The bus module and FI 3 should always be the last physical participants on the system bus.
POWERLINK Bus module – Supplementary manual options for NORD - Frequency Inverters
Relevant
bus system
Serial
No.
Step
Comments
System bus
1
Set up system bus
Couple all devices together.
2
Set termination resistor
DIP switch "Bus termination, system bus" on field bus
module(SK xU4-…) "ON"
DIP switch "Bus termination, system bus" on FI 3 "ON" All other DIP switches to "OFF"
3
Set system bus addresses
For preference, set the FI addresses via DIP switches (see manual BU0200):
Bus module: fixed (at 5) FI 1: to 32 FI 2: to 34 FI 3: to 36
4
System bus baud rate
Set the FI to 250 kBaud (For FI: SK 200E this is pre-set accordingly)
5
System bus communication
Make settings on each FI
(P509): { 3 } "System bus" (P510 [-01 … -02]): { 0 } "Auto" (P543 [-01]): { 1 } "Actual frequency" (P546 [-01]): { 1 } "setpoint frequency"
Field bus
6
Configure bus module for field bus
See Section "Addressing" (e.g.: DIP switch on the bus module or corresponding parameter)
System bus
7
Monitoring at system bus level
(P151): { 200 } (P120 [-01]) { 1 } or { 2 }
System bus
8
Checking system bus communication
(P748): "System bus status" (P740 [-01]): "Control word" (P740 [-02]): "Setpoint 1" (P741 [-01]): "Status word" (P741 [-02]): "Actual value 1" (P173): "Module status"
Field bus
9
Checking field bus communication
(P173): "Module status" (P176): "PZD Bus In" (P177): "PZD Bus Out"
Sequence
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4 Communication and Protocol
State
Explanation
Init
No communication of process data and parameters
The bus is monitored for POWERLINK frames. If no corresponding frame is received within the set time window (timeout), the interface switches directly to the status BASIC_ETHERNET. However, if a POWERLINK communication is detected before the time expires, the interface switches directly to the status PRE_OPERATIONAL_1.
Pre- Operational 1
Parameter communication active, no process data communication
The CN waits for the reception of an SoC frame and then switches to the status PRE_OPERATIONAL_2. If the red LED lights up in this state, this means that the Manager has failed.
Pre- Operational 2
Parameter communication active, no process data communication
In this state, the interface is usually configured by the Manager. After this, a command is given to switch to the state READY TO OPERATE. If the red LED lights up in this state, this means that the Manager has failed.
Ready To Operate
Parameter communication active, restricted process data communication
Configuration of the interface is complete. Normal cyclic and asynchronous communication. The transmitted PDO data correspond to the PDO Mapping. However, cyclic data are not evaluated. If the red LED lights up in this state, this means that the Manager has failed.
Initialisation
not Active
Basic Ethernet
Pre-Operational 1
Operational
Ready to Operate
Pre-Operational 2
Error Condition
4. Communication and Protocol
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4.1 NMT State Machine
The NMT State Machine defines various communication states of the module.
Figure 2: NMT State Machine
POWERLINK Bus module – Supplementary manual options for NORD - Frequency Inverters
State
Explanation
Operational
Parameter communication active, process data communication active
The interface is in the OPERATIONAL state.
Basic Ethernet
In this state, parameter communication is only possible via UDP/IP. If a POWERLINK communication is detected during this state, the interface switches to the state PRE OPERATIONAL 1. If the red LED lights up in this state, this means that the Manager has failed.
Stopped
Output data are not sent out and no input data are delivered. This state can only be achieved and exited by a corresponding command from the Manager.
Table 5: Explanation of the NMT State Machine
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4.2 Processing of Process Data in the Frequency Inverter
In the process data area (PZD), control words and setpoints are transferred from the master to the frequency inverter and in return, status words and actual values are sent from the frequency inverter to the master. The structure of the PZD area is always the same in terms of the sequence of its elements (words), however, dependent upon direction of data Master Slave / Slave Master, it is described differently. Each word has a length of 16 Bit. To communicate 32 Bit values (e.g. position values), 2 words are required (e.g setpoint 1 and setpoint 2).
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