Rockwell Automation 193-EPRB User Manual

BULLETIN 193

E1 Plus PROFIBUS Module

CATALOG NUMBER 193-EPRB

USER MANUAL

Important User Information

WARNING

IMPORTANT

ATTENTION

SHOCK HAZARD

BURN HAZARD

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.ab.com/manuals/gi) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.

Throughout this manual, when necessary we use notes to make you aware of safety considerations.

Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

Identifies information that is critical for successful application and understanding of the product.

Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you:

• identify a hazard

• avoid a hazard

• recognize the consequence

Labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.

Labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be dangerous temperatures.

Table of Contents

Chapter 1 Installation and Wiring

Chapter 2 Protection Functions

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Trip Status / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Trip Resetting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Trip and Warning Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Overload and Phase Loss Protection . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Overload Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Jam Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Jam Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Jam Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Underload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Underload Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Communication Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Comm Fault Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Communication Idle Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Comm Idle Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Chapter 3 PROFIBUS Configuration

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Acyclic Parameter Access (DP-V1). . . . . . . . . . . . . . . . . . . . . . . . 3-1

Cyclic Parameter Access (DP-V0). . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Initial Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Control- and Status Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Control Register. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Status Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Parameter Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Program Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Resetting to the Factory Default Values. . . . . . . . . . . . . . . . . . . . 3-4

Parameter Group Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Monitor Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Advanced Setup Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Reset/Lock Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

I/O Setup Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Trip History Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

PROFIBUS Setup Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

iii Publication 193-UM010A-EN-P – January 2008

Chapter 4 Troubleshooting

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

PROFIBUS Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Power-Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Run Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Configuration Error Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fatal Error Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

PROFIBUS Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . 4-2

Network Status LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

DP-V1 Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Input and Output Troubleshooting Procedures. . . . . . . . . . . . . . . . . 4-6

Trip and Warning Troubleshooting Procedures. . . . . . . . . . . . . . . . . 4-8

Appendix A - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B PROFIBUS Information

Structure of the "Set Prm Data"-telegram . . . . . . . . . . . . . . . . . . . . . B-1

Electronic Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Set Slave Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Supported Baud Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

PROIFIBUS Identity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Identification and Maintenance (I&M). . . . . . . . . . . . . . . . . . . . . B-4

Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Installation Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

New Product Satisfaction Return . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Installation and Wiring

ATTENTION

Chapter

Introduction

The purpose of this chapter is to provide the necessary instructions to successfully install a 193-EPRB PROFIBUS Module to an E1 Plus Overload Relay and properly connect to a PROFIBUS network.

To prevent electrical shock, disconnect from power source before installing or servicing. Install in suitable enclosure. Keep free from contaminants.

The side mount module contains ESD (electrostatic discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing, or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to Rockwell Automation publication 8000-4.5.2, “Guarding Against Electrostatic Damage”, or any other applicable ESD protection handbook.

The purpose of this document is to serve as a guide for proper installation. The National Electrical Code and any other governing regional or local code will take precedence. Rockwell Automation cannot assume responsibility for the compliance or proper installation of the side mount module or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

An incorrectly applied or installed side mount module can result in damage to the components or reduction in product life. Wiring or application errors such as supplying incorrect or inadequate supply voltage, or operating/storing in excessive ambient temperatures may result in malfunction of the product.

Only personnel familiar with the side mount module and associated machinery should plan to install, set up, and maintain the system. Failure to comply may result in personal injury and/or equipment damage.

This is a Class A product. In a domestic environment, this product may cause radio interference, in which case, the user may be required to take adequate measures.

1-2 Installation and Wiring

PROFIBUS Connector

Network Status LED

Power Supply Connector

I/O Connector

#2 Driver

0.7 - 1.1 N.m (6 - 10 lb-in)

7mm (.28 in)

0.5 - 0.6 N.m (4.4 - 5.3 lb-in)

0.6mm X 3.5mm Blade (.02 in X .14 in Blade)

Features

Installation

Figure 1.1 Features

Figure 1.2 Installation [1] Figure 1.3 Installation [2]

Figure 1.4 Installation [3]

Installation and Wiring 1-3

OUTA

(B300)

SSV

IN2

IN1

A1 (+)

A2 (

)

(20.4 - 26.4 VDC)

9. Housing

NC NC B-Line RTS GND BUS +5V BUS OUT NC A-Line NC SHIELD

Wiring

Figure 1.5 Wiring Diagram

Table 1.1 Wire and Size Torque Specifications

1X 2X

24…12 AWG 24…16 AWG

5 lb.-in

1X 2X

0.2…2.5 mm

0.25…1 mm

0.55 N•m

1X 2X

0.2…2.5 mm

0.2…1 mm

0.55 N•m

Publication 193-UM010A-EN-P – January 2008

1-4 Installation and Wiring

Dimensions

Figure 1.6 Dimension Diagram

Table 1.2 Dimension Specifications

Contactor Cat. No. E1 Plus Cat. No. ABCDE FGHJ KL

100-C09, -C12, -C16,

-C23 100-C30, -C37 193*EE_D mm

100-C43 mm

100-C60, -C72, -C85 193*-EE_E mm

193*-EE_B mm

(in)

67 (2.64)

71.5 (2.82)

94 (3.70)

148 (5.83)

191.6 (7.54)

85.2 (3.35)

101.2 (3.98)

120.4 (4.74)29(1.14)

24.5 (.96)

13.9 (.55)35(1.38)60(2.36)

18.4 (.74)45(1.77)60(2.36)

23.8 (.94)55(2.16)

100 (3.94)

86.5 (3.40)2(.08)

104 (4.09)2(.08)

126 (4.94)2(.08)

4.5 (.17)22(.86)

5.4 (.21)22(.86)

Publication 193-UM010A-EN-P – January 2008

Protection Functions

IMPORTANT

ATTENTION

Introduction

Trip Status / Identification

Trip Resetting

The purpose of this chapter is to provide detailed information regarding the protective trip and warning functions that the 193-EPRB PROFIBUS Module adds to the E1 Plus Overload Relay. In this chapter, you will find considerable mention given to parameters as they relate to these functions. For complete descriptions of the programming parameters, refer to Chapter 3 -

PROFIBUS Configuration.

The PROFIBUS Module determines trip status and identification through monitoring of reference signals inside the E1 Plus Overload Relay. On power-up, it assumes that the E1 Plus Overload Relay is in a non-tripped condition. For definitive feedback on trip status of the E1 Plus Overload Relay, one of the PROFIBUS module inputs may be wired to the N.O. auxiliary contact (terminals 97 and 98) of the E1 Plus Overload Relay. Parameters 28 and 29 are used to configure the assignment of the inputs. For this function, use the “OL Contact” configuration.

The following options are available for resetting a tripped E1 Plus Overload Relay with a PROFIBUS module:

• Blue mechanical reset button located on the front of the E1 Plus Overload Relay

• Setting Parameter 19, Trip Reset, to “Reset”

• Setting the "Trip Reset"-bit bit in the Control Register

• Using a push button (N.O. contact configuration) wired to one of the PROFIBUS

Module inputs, programming the corresponding input assignment parameter (28 or 29) to “Trip Reset”

Setting parameter 11, Reset Mode, to “Automatic” does not result in other reset commands being ignored.

Trip and Warning Enable

Overload and Phase Loss Protection

1 Publication 193-UM010A-EN-P – January 2008

Parameter 8, Trip Enable, allows the installer to enable or disable the jam trip protective function. Parameter 9, War n i ng Enable, allows the installer to enable or disable the overload, jam and

underload warning protective functions.

The Trip Enable settings should not be altered during machine operation, as unexpected behavior could occur. This may result in an unintended actuation of controlled industrial equipment, with the potential for machine damage or serious injury to personnel.

Thermal overload and phase loss trip protection is provided exclusively by the E1 Plus Overload Relay. The E1 Plus Overload Relay provides uninterrupted protection to the motor, even in the

2-2 Protection Functions

IMPORTANT

event of a PROFIBUS Module failure. Settings for FLA and trip class are found directly on the E1 Plus Overload Relay.

The reset mode DIP switch adjustment is overridden by the PROFIBUS module parameter 11, OL Reset Mode, while the PROFIBUS module is powered.

Overload Warning

The PROFIBUS Module continuously monitors the E1 Plus Overload Relay's percentage of thermal utilization signal. Parameter 2,%Therm Utilized, provides this value.

Parameter 12, OL Warning Level, is used to adjust the setpoint to alert for an impending overload trip and is adjustable from 0…100% TCU.

The PROFIBUS Module will indicate an overload warning if all the following conditions are met:

• No warning currently exists

• Overload warning is enabled

• %Therm Utilized is equal to or greater than OL Warning Level

When the overload warning conditions are satisfied, the following will occur:

• Bit 0 in Parameter 4, War n i n g Status, will go to “1”

• Bit 1 of Parameter 5, Device Status, will go to “1”

Jam Protection

%Therm Utilized will stabilize at a value of approximately 88% with the motor operating continuously at rated current.

Motor current greater than the motor's nameplate rating can indicate a high overload or stall condition, such as an overloaded conveyor or jammed gear. These conditions can result in overheating of the motor, and equipment damage. Rapid jam fault detection helps to minimize damage and loss of production.

By continuously monitoring the motor current level signal as a percentage of the E1 Plus Overload Relay's dial FLA setting, the PROFIBUS module allows jam trip and warning capability.

Jam Trip

The following parameters are available for configuring the PROFIBUS Module's jam trip performance:

• Parameter 13, Jam Inhibit Time, allows the installer to inhibit a jam trip from occurring

during the motor starting sequence. It is adjustable from 0…250 seconds.

• Parameter 14, Jam Trip Delay, allows the installer to define the time period a jam

condition must be present before a trip occurs. It is adjustable from 0.5…25.0 seconds.

• Parameter 15, Jam Trip Level, allows the installer to define the current at which the E1

Plus Overload Relay will trip on a jam. It is user-adjustable from 150…600% of the FLA dial setting.

Publication 193-UM010A-EN-P – January 2008

Protection Functions 2-3

IMPORTANT

The PROFIBUS Module will command the E1 Plus Overload Relay to trip if all the following conditions are met:

• No trip currently exists

• Jam Protection is enabled

• Jam Inhibit Time has expired

• The motor current is greater than the Jam Trip Level for a time period greater than the

Jam Trip Delay

When the conditions for a jam trip are satisfied, the following will occur:

• Bit 2 in Parameter 3, Trip Status, will go to “1”

• Bit 0 in Parameter 5, Device Status, will go to “1”

• The E1 Plus Overload Relay's trip relay contacts (95 and 96) will open

• Out A will be placed in their Protection Fault State (if so programmed)

The Protection Fault State of OUT A is defined by parameter 22 (OUTA Pr FltState) and parameter 23 (OUTA Pr FltValue).

The jam inhibit timer starts after the load current transitions from 0 A to 30% FLA. The PROFIBUS Module does not begin monitoring for a jam condition until the Jam Inhibit Time expires.

Underload Protection

Jam Warning

Parameter 16, Jam Warn Level, allows the installer to define the current at which the PROFIBUS Module will indicate a warning. It is user-adjustable from 100…600% FLA.

The PROFIBUS Module will indicate a Jam warning if:

• No warning currently exists

• Jam Warning is enabled

• Jam Inhibit Time has expired

• The motor current is equal to or greater than the Jam Warn Level

When the Jam Warning conditions are satisfied, the following will occur:

• Bit 2 in Parameter 4, War n in g Status, will go to “1”

• Bit 1 in Parameter 5, Device Status, will go to “1”

The Jam Warning function does not include a time delay feature. Once the Jam Inhibit Time has expired, the Jam Warning indication is instantaneous.

Motor current less than a specific level may indicate a mechanical malfunction in the installation, such as a torn conveyor belt, damaged fan blade, broken shaft, or worn tool. Such conditions may not harm the motor, however, rapid detection may help to minimize equipment damage and loss of production.

Publication 193-UM010A-EN-P – January 2008

2-4 Protection Functions

IMPORTANT

Underload Warning

The following parameters are available for configuring the PROFIBUS Module's underload warning performance:

• Parameter 17, UL Inhibit Time, allows the installer to inhibit an underload indication

from occurring during the motor starting sequence. It is adjustable from 0…250 seconds.

• Parameter 18, UL Warn Level, allows the installer to define the current at which the

PROFIBUS Module will indicate a warning. It is user-adjustable from 30…100% of the FLA dial setting.

The PROFIBUS Module will immediately indicate an Underload warning if:

• No warning currently exists

• Underload Warning is enabled

• UL Inhibit Time has expired

• The motor current is less than the UL Warn Level

When the Underload Warning conditions are satisfied, the following will occur:

• Bit 3 in Parameter 4, War n i n g Status, will go to “1”

• Bit 1 of Parameter 5, Device Status, will go to “1”

The Underload Warning function does not include a time delay feature. Once the UL Inhibit Time has expired, the Underload warning indication is instantaneous.

Communication Fault Protection

Communication Idle Protection

A disruption of the communication link between the E1 Plus PROFIBUS Module and a PROFIBUS network can result in the loss of application control and/or critical process diagnostic data. Rapid communication fault detection helps minimize potential damage due to uncontrolled or unmonitored applications.

Comm Fault Warning

The PROFIBUS Module will indicate a Comm Fault warning if:

• No warning currently exists

• Comm Fault Warning is enabled

• The PROFIBUS Module experiences a loss of communication

When the Comm Fault warning conditions are satisfied, the following will occur:

• The Network Status LED will go out

• Bit 5 in Parameter 4, War n i n g Status, will go to “1”

• Bit 1 of Parameter 5, Device Status, will go to “1”

The Comm Fault State of OUT A is defined by Parameter 24 (OUTA Pb FltState) and parameter 25 (OUTA Pb FltValue).

When a programmable controller is placed into the program mode, the execution of its ladder program is suspended, and any connected networks go to an idle state. If inadvertent, this can result in the loss of application control and/or critical process diagnostic data. Rapid

Publication 193-UM010A-EN-P – January 2008

+ 28 hidden pages