Toshiba ETH-100 User Manual

ASD INTERFACE SERIES

ICC

INDUSTRIAL CONTROL COMMUNICATIONS, INC.

INDUSTRIAL CONTROL COMMUNICATIONS, INC.INDUSTRIAL CONTROL COMMUNICATIONS, INC.

ETH-100

ETHERNET COMMUNICATIONS INTERFACE

FOR TOSHIBA ADJUSTABLE SPEED DRIVES

March 2003 ICC #10449-2.000-000

Introduction

Thank you for purchasing the ICC, Inc. ETH-100 Ethernet Communications Interface for the Toshiba 7-Series, 9-Series and VF-nC1 Series Adjustable Speed Drives. Before using the ETH-100 interface, please familiarize yourself with the product and be sure to thoroughly read the instructions and precautions contained in this manual. In addition, please make sure that this instruction manual is delivered to the end user of the drive units with which the ETH-100 interface is connected, and keep this instruction manual in a safe place for future reference or drive/interface inspection.

This instruction manual describes the device specifications, wiring methods, maintenance procedures, supported functions and usage methods for the ETH-100 Ethernet communications interface.

In conjunction with this manual, the following manuals are supplied by Toshiba, and are essential both for ensuring a safe, reliable system installation as well as for realizing the full potential of the ETH-100 interface:

• Toshiba TOSVERT VF-S7 Series Instruction Manual

• Toshiba TOSVERT VF-S9 Series Instruction Manual

• Toshiba TOSVERT VF-A7 Series Instruction Manual

• Toshiba TOSVERT VF-nC1 Series Instruction Manual

• Toshiba G7 Series Operation Manual

• Toshiba VF-S7 Industrial Inverter Serial Communications Option Manual

If you do not have copies available of the documents relevant to your installation, please contact Toshiba or your local Toshiba distributor to obtain them, or copies may be downloaded from http://www.tic.toshiba.com to availability).

Before continuing, please take a moment to ensure that you have received all materials shipped with your kit. These items are:

• ETH-100 interface in DIN rail mountable case

• 2 meter DB9-RJ45 MMI port cable (part number 10425)

• This manual

(subject

ETH-100 Ethernet Interface User's Manual

Part Number 10449-2.000-000

Printed in U.S.A.

Industrial Control Communications, Inc. reserves the right to make changes

and improvements to its products without providing notice.

Notice to Users

INDUSTRIAL CONTROL COMMUNICATIONS, INC.’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE-SUPPORT DEVICES OR SYSTEMS. Life-support devices or systems are devices or systems intended to sustain life, and whose failure to perform, when properly used in accordance with instructions for use provided in the labeling and user's manual, can be reasonably expected to result in significant injury.

No complex software or hardware system is perfect. Bugs may always be present in a system of any size. In order to prevent danger to life or property, it is the responsibility of the system designer to incorporate redundant protective mechanisms appropriate to the risk involved.

Usage Precautions

Operating Environment

• Please use the ETH-100 only when the ambient temperature of the environment into which the unit is installed is within the following specified temperature limits:

Operation Storage

• Avoid installation locations that may be subjected to large shocks or vibrations.

• Avoid installation locations that may be subjected to rapid changes in temperature or humidity.

: -10 ∼ +50°C (+14 ∼ +122°F)

: -40 ∼ +85°C (-40 ∼ +185°F)

Installation and Wiring

• Proper ground connections are vital for both safety and signal reliability reasons. Ensure that all electrical equipment is properly grounded.

• Route all communication cables separate from high-voltage or noiseemitting cabling (such as ASD input/output power wiring).

ASD Connections

• Do not touch charged parts of the drive such as the terminal block while the drive’s CHARGE lamp is lit. A charge will still be present in the drive’s internal electrolytic capacitors, and therefore touching these areas may result in an electrical shock. Always turn all drive input power supplies OFF, and wait at least 5 minutes after the CHARGE lamp has gone out before connecting communication cables.

• To avoid misoperation, do not connect any ETH-100 terminals to either the ASD’s E/GND terminals, the motor, or to any other power ground.

• When making common serial connections between the ETH-100 and ASDs, do not use cables that exceed 5 meters in length.

• For further drive-specific precaution, safety and installation information, please refer to the appropriate documentation supplied with your drive.

• Internal drive EEPROMs have a limited life span of write cycles. Observe all precautions contained in this manual and your ASD manual regarding which drive registers safely may and may not be repetitively written to.

• Because the ETH-100 derives its control power from the connected drives, removing power to all connected drives will also cause the ETH-100 to lose power.

TABLE OF CONTENTS

1. The Point Database Concept .......................................................6

2. Mechanical Diagrams ...................................................................7

2.1

Enclosure ..............................................................................................7

2.2

Mounting Clip ........................................................................................8

2.3

External Interface..................................................................................9

3. Feature Summary........................................................................10

4. Installing The Interface...............................................................13

4.1

Installation for G7 ASDs......................................................................13

4.2

Installation for S7, S9, A7 and VF-nC1 ASDs .....................................15

5. Grounding....................................................................................17

6. Environmental Specifications....................................................18

7. Maintenance And Inspection .....................................................19

8. Storage And Warranty ................................................................20

8.1

Storage ...............................................................................................20

8.2

Warranty .............................................................................................20

9. LED Indicators.............................................................................21

9.1

Module and Ethernet Indicators ..........................................................21

9.2

ASD Port Indicators ............................................................................21

9.3

MMI Port Indicators.............................................................................22

10. Internal Battery...........................................................................23

11. Console Access .........................................................................24

11.1 RS232 .................................................................................................24

11.1.1 Requirements .............................................................................24

11.1.2 Connection .................................................................................24

11.1.3 Application Configuration ...........................................................24

11.2 Telnet ..................................................................................................27

11.2.1 Requirements .............................................................................27

11.2.2 Connection .................................................................................27

11.2.3 Application Configuration ...........................................................27

11.3 Command Overview............................................................................28

12. Modbus TCP/IP ..........................................................................32

12.1 Drive Channel Access ........................................................................ 32

12.2 Supported Modbus Functions............................................................. 32

12.3 Modbus/Drive Register Mappings ...................................................... 32

12.3.1 Point Mapping............................................................................ 32

12.3.2 Direct (Implicit) Mapping ............................................................ 33

12.3.3 Universal Access Registers....................................................... 34

12.4 Exceptions and Troubleshooting ........................................................ 36

12.4.1 Common Error Causes .............................................................. 36

12.4.2 General ASD Access Notes....................................................... 37

13. Embedded Web Server..............................................................38

13.1 Authentication..................................................................................... 39

13.2 Device Setup Page............................................................................. 40

13.3 Point Setup Page ............................................................................... 42

13.4 Point Monitor Page............................................................................. 44

14. Firmware Updates......................................................................46

14.1 Requirements ..................................................................................... 46

14.2 Connection ......................................................................................... 46

14.3 Using The RFU Utility......................................................................... 47

14.3.1 Required Files............................................................................ 47

14.3.2 First-time configuration .............................................................. 47

14.3.3 Transmitting Firmware Files ...................................................... 50

14.4 Wrap-Up ............................................................................................. 51

15. Notes ...........................................................................................52

1. The Point Database Concept

The heart of the ETH-100’s mapping capabilities is an element called the “point database” (refer to Figure 1). The point database is entirely userconfigurable, and provides the end-to-end mapping information that allows primary (Ethernet) network requests to be routed to the correct locations on the secondary network (the ASD ports), while at the same time ensuring that the content of the request will be understood once it gets there. Additionally, the point database provides the added benefit of “data mirroring”, whereby current copies of point values (ASD registers) are maintained locally within the ETH100 itself. This greatly reduces the primary network’s request-to-response latency time, as requests (read or write) can be entirely serviced locally, thereby eliminating the time required to execute a secondary network transaction.

When properly configured, the gateway will become essentially “transparent” on the network, and the primary network master can engage in a seamless dialogue with one or more secondary network devices (ASDs).

Ethernet

Network

Point

Database

Figure 1: The Point Database Concept

ASD

Ports

2. Mechanical Diagrams

2.1 Enclosure

Figure 2: Enclosure Dimensions (units are inches)

2.2 Mounting Clip

Figure 3: Mounting Clip Dimensions (units are inches)

2.3 External Interface

Ethernet Network

Configuration

Swirches

Chassis

Ground

Figure 4: Bottom View

MMI Port Channel A Channel B Channel C

Figure 5: Front View

3. Feature Summary

Primary Network

IEEE 802.3 10BaseT Ethernet compliant. Shielded RJ45 connector accepts standard CAT5-type 8-conductor unshielded twisted-pair (UTP) patch cables.

Secondary Network

ASD common serial: The ETH-100 provides support for simultaneous

connection of three Toshiba 7-series, 9-series or VF-nC1 ASDs via the drives’ common serial (aka logic level) communication ports. ASD connections use the same standard RJ45 style 8-conductor UTP patch cables: any standard CAT5 Ethernet cable (found in most electronics stores) 5 meters or less in length can be used to connect the ETH-100 to the drives.

Power Supply

Self-contained. Powered directly from the connected drives. Drives can be connected to the ETH-100 on any channel (A, B or C) in any order or combination. When more than 1 drive is connected to the unit, the ETH-100 will draw its control power from the drive with the highest power supply voltage.

Supported Protocols

• Primary Network

o Schneider Electric Modbus TCP/IP, release 1.0.

• Secondary Network

o Toshiba ASD (common serial)

Text-Based Console Configuration

Basic unit configuration is performed via a text-based console interface, available locally over RS232 by using the included MMI cable and a standard PC terminal program such as Microsoft Windows HyperTerminal®, or over Ethernet via a Telnet session.

Macromedia® Flash-Enabled Embedded Web Server

Advanced unit configuration and drive monitoring/control are also provided via an embedded web server using the HTTP protocol. The ETH-100’s web server feature provides direct data access and control via standard web browsers such as Microsoft Internet Explorer and Netscape Navigator. The latest version of Macromedia Flash Player browser plug-in is required.

Point File-Based Configuration

A point file (primary / secondary network mapping definition file) is stored in the unit’s internal battery-backed file system. Point files can also be uploaded from / downloaded to a PC, which provides the capability for PC-based file backup and easy configuration copying to multiple units. Sample point files

Conformance Class 0 and partial Class 1 compliant. Allows up to 8 simultaneous Modbus TCP/IP client connections.

and related documentation can also be downloaded from our web site, uploaded to a unit, and custom-modified to suit a specific application.

Drive AutoScan Algorithm

ASD common serial port connections are automatically established and continuously monitored (when points are defined for that drive). No drive configuration needs to be performed to connect the ETH-100 to the drives. Just plug it in – it’s that simple.

Modbus TCP/IP Universal Access Registers

Modbus TCP/IP holding registers 9998 and 9999 provide an easy method of directly accessing any drive register without the necessity of first defining an internal point. This is typically convenient when asynchronous access to large blocks of non-control data is desired, such as when uploading or downloading an entire device configuration set over the Ethernet network. Refer to section

12.3.3 for more information.

Selectable Grounding

Switch SW1 #2 allows the ground plane to be split into 2 different sections: one for the main control circuitry and another for the Ethernet network connector shield and associated magnetics. The latter ground point is accessible for external termination via the GND screw terminal located on the bottom of the unit. Refer to section 5 for more information related to grounding.

Indicators

• 1 green “LNK” LED that is on whenever a valid Ethernet connection is detected.

• 1 red “ACT” LED that flashes whenever data is transferred across the Ethernet network.

• 1 bicolor red/green “MS” LED that indicates module status information.

• 1 bicolor red/green “NS” LED that indicates network status information.

• 2 green LEDs on each of the drive communication connectors and on the

MMI port connector.

Refer to section 9 for more detailed information about the LED indicators and their meanings.

MMI Port Connector

RS232-level. Use the DB9-to-RJ45 MMI cable supplied with the ETH-100 kit to interface with the unit for either console-based configuration, point file upload/download, or flash firmware downloading.

Field-Upgradeable

As new firmware becomes available, the ETH-100 unit can be upgraded in the field by the end-user. Refer to section 14 for more information.

Versatile 3-Way DIN-Rail Mounting System

The unit’s enclosure is provided with a mounting clip attached to the rear of the unit. This clip allows the unit to be mounted 3 different ways:

• For DIN rail mounting, snap the mounting clip onto a standard DIN rail, and then snap the unit enclosure onto the clip’s retaining tabs. This allows easy removal or repositioning of the unit on the DIN rail during wiring.

• For panel mounting, the mounting clip can be bolted directly to a flat panel via the two bolt holes at the top and bottom of the clip. Refer to section 2.2 for mounting clip mechanical details. Once the mounting clip is securely attached to the panel, the unit enclosure can be snapped onto the clip’s retaining tabs.

• For fixed DIN rail mounting, a combination of the above two techniques can be employed. First, snap the mounting clip onto a DIN rail and position it in its desired location. Then, the mounting clip can be bolted to the DIN rail support panel, securing it in place. Lastly, the unit can be snapped onto the fixed mounting clip.

In all cases, the unit can be easily unsnapped from the mounting clip to temporarily provide easier access to the configuration switches, chassis ground terminal or network connector.

4. Installing The Interface

The ETH-100 connects to each drive via the drive’s common serial (logic level) communication port, typically located on either the main drive control board (G7), on the front of the drive enclosure under a small snap-on cover (A7, S9), on the right-hand side of the drive enclosure under a small snap-on cover (S7), or on the bottom side of the drive enclosure (VF-nC1). Although in general no drive parameters need to be configured in order to use the gateway, it is advantageous to check that the drive’s common serial communication data rate is set to its maximum speed. Because the ETH-100 will communicate to each drive only at the drive’s configured data rate, this will provide the fastest response time for drive-to-network data transfers. For information on checking the drive’s common serial communication data rate, refer to the appropriate manual supplied with your drive.

Note that the common serial communication parameters of each drive are handled independently by the ETH-100, which means that different drive families may be connected to different channels of the unit in any combination, and that the drives connected to each channel may simultaneously communicate to the unit at completely different baud rates, parity settings, etc.

Drives can be connected to any ETH-100 channel in any order or combination. When more than one drive is connected to the unit, the gateway will draw its control power from the source with the highest power supply voltage.

Installation of the ETH-100 should only be performed by a qualified technician familiar with the maintenance and operation of the connected drives. To install the ETH-100, complete the steps outlined in the following sections related to your specific drive.

4.1 Installation for G7 ASDs

3. Attach the mounting clip and interface enclosure in your desired manner

CAUTION!

be connected have been turned OFF and are locked and tagged out.

DANGER!

electrolytic capacitors to discharge before proceeding to the next step. Do not touch any internal parts with power applied to the drive, or for at least 5 minutes after power to the drive has been removed. A hazard exists temporarily for electrical shock even if the source power has been removed. Verify that the CHARGE LED has gone out before

continuing the installation process.

(refer to page 12 for more information).

Verify that all input power sources to the drives to

Wait at least 5 minutes for the drive’s

4. Remove the drive’s front cover / open the drive’s cabinet door (refer to the appropriate drive manual for instructions how to do this).

5. The drive’s LCD panel (also called the “Electronic Operator Interface” or “EOI”) can communicate with the drive via either the RS485/RS232 channel (CNU1/CNU1A) or the common serial channel (CNU2/CNU2A). Because the interface uses the common serial channel, the LCD panel must be configured to use the RS485/RS232 channel. If the drive to be connected is currently using CNU2 (on the drive control board) and CNU2A (on the LCD panel), then this connection must first be switched over to CNU1 (on the drive control board) and CNU1A (on the LCD panel). Refer to Toshiba’s documentation for any precautions or notices regarding this connection change. If the LCD panel is already connected via the RS485/RS232 channel, then no change is required.

6. Configure the drive’s LCD panel to communicate via the RS485/RS232 channel by setting parameter ”Communication Setting

Parameters.. Communication Settings.. Select LCD Port Connection” to “RS485/232 serial”.

7. Connect the drive’s common serial communication port (CNU2) to one of the ASD channels of the interface with the communication cable (communication cable is not included with the ETH-100 kit). When choosing cables for this connection, standard 24 AWG category 5 (CAT5) unshielded twisted-pair (UTP) 8-conductor cables found in Ethernet networks in most office environments can be used. The maximum allowable length for these cables is 5 meters. Although there are many varieties and styles of CAT5 UTP cables available, ICC strongly recommends using only high-quality cables from reputable manufacturers to guarantee optimal noise immunity and cable longevity. Ensure that each end of the cable is fully seated into the modular connectors, and route the cable such that it is located well away from any drive input power or motor wiring. Also take care to route the cable away from any sharp edges or positions where it may be pinched.

8. Reinstall the drive’s front cover / close the drive’s cabinet door.

9. Repeat steps 1-8 to connect other drive(s) as needed.

10. Connect the Ethernet network cable to the shielded RJ45 connector marked “Network” on the bottom of the unit. If a ground cable is going to be used, attach the ground cable to the screw terminal marked “GND” on the bottom side of the unit (refer to section 5). Ensure that the network cable is fully seated into the modular connector, and route the cable such that it is located well away from any drive input power or motor wiring. Also take care to route the cable away from any sharp edges or positions where it may be pinched.

11. Take a moment to verify that the interface and all primary and secondary network cables have sufficient clearance from drives, motors, or powercarrying electrical wiring.

12. Turn the power sources to all connected drives ON, and verify that the drives function properly. If the drives do not appear to power up, or do not

function properly, immediately turn power OFF. Repeat steps 1 and 2 to remove all power from the drives. Then, verify all connections. Contact ICC or your local Toshiba representative for assistance if the problem persists.

4.2 Installation for S7, S9, A7 and VF-nC1 ASDs

3. Attach the mounting clip and interface enclosure in your desired manner

4. Remove the drive’s common serial communication port cover if it has one

5. Connect the drive’s common serial communication port to one of the ASD

6. Repeat steps 1, 2, 4 and 5 to connect other drive(s) as needed.

7. Connect the Ethernet network cable to the shielded RJ45 connector

CAUTION!

be connected have been turned OFF and are locked and tagged out.

DANGER!

continuing the installation process.

(refer to page 12 for more information).

(refer to the appropriate drive manual for instructions how to do this). Do not discard this cover, as it should be reinstalled to minimize contamination of the port’s electrical contacts if the interface is ever disconnected from the drive.

channels of the interface with the communication cable (communication cable is not included with the gateway kit). When choosing cables for this connection, standard 24 AWG category 5 (CAT5) unshielded twisted-pair (UTP) 8-conductor cables found in Ethernet networks in most office environments can be used. The maximum allowable length for these cables is 5 meters. Although there are many varieties and styles of CAT5 UTP cables available, ICC strongly recommends using only high-quality cables from reputable manufacturers to guarantee optimal noise immunity and cable longevity. Ensure that each end of the cable is fully seated into the modular connectors, and route the cable such that it is located well away from any drive input power or motor wiring. Also take care to route the cable away from any sharp edges or positions where it may be pinched.

marked “Network” on the bottom of the unit. If a ground cable is going to be used, attach the ground cable to the screw terminal marked “GND” on the bottom side of the unit (refer to section 5). Ensure that the network

Verify that all input power sources to the drives to

Wait at least 5 minutes for the drive’s

cable is fully seated into the modular connector, and route the cable such that it is located well away from any drive input power or motor wiring. Also take care to route the cable away from any sharp edges or positions where it may be pinched.

8. Take a moment to verify that the interface and all primary and secondary network cables have sufficient clearance from drives, motors, or powercarrying electrical wiring.

9. Turn the power sources to all connected drives ON, and verify that the drives function properly. If the drives do not appear to power up, or do not function properly, immediately turn power OFF. Repeat steps 1 and 2 to remove all power from the drives. Then, verify all connections. Contact ICC or your local Toshiba representative for assistance if the problem persists.

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