User Manual
Contents
1. REGULATOR BOARD v a 9 2 Bo Le A aed teed 0 2222 0 ki P oN ih Pe ai 11 56 2 1 5 8 060 a AAS ii I DAUGHTER BOARD NETWORK BOARD l AIR FLOM DJ L HH 5 oes 0 Li m J i lH Figure 2 2 GV3000 Drive 1 5 HP PAGE 10 11 10 OCTOBER 1998 2 INSTALLATION REGULATOR BOARD 18 DO DAUGHTER BOARD NETWORK BOARD 805534 8 Figure 2 3 GV3000 Drive 7 5 10 HP CHAPTER 2 INSTALLATION 10 OCTOBER 1998 PAGE 12 REGULATOR BOARD Pan P2. 25 4 42 Drive Ready Status See a a ae 26 4 2 Network Access to Drive Registers a 26 4 3 Network Diagnostics wete asa Qa Qaya Dawa WD Sa a a ee a ea 27 APPENDIX A ACCESS TO DRIVE DATA REGISTERS 29 ALAS o Drive 29 A125 sDriVe CONTO i te eee a 29 Alzi Ay 29 1 2 2 Register 32 Drive Control 30 A1 2 3 Register 33 Network Speed torque 30 APPENDIX B DEFAULT TUNE CONFIGURATION REGISTERS a 31 5 10 OCTOBER 1998 PREFACE SAFETY NOTICES a DANGER Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install it Read and understand this manual in its entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life b DANGER The user is responsible for conforming to the NEC CEC and all other applicable local codes Wiring practices grounding disconnects and over current protection are of particular importance Failure to observe this precaution could
3. APG User Manual for the HEC GV3 RTU Option Card RTU MODBUS Network Communication Option Board for use with Reliance Electric GV3000 AC Drive Second Edition 10 October 1998 Preliminary MAN0183 02 PREFACE 10 OCTOBER 1998 PAGE 2 PREFACE This manual explains how to use the Horner Electric s RTU MODBUS Network Communication Option Board for use with Reliance Electric GV3000 AC Drive Copyright C 1998 Horner Electric Inc 640 North Sherman Drive Indianapolis Indiana 46201 All rights reserved No part of this publication may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or computer language in any form by any means electronic mechanical magnetic optical chemical manual or otherwise without the prior agreement and written permission of Horner Electric Inc All software described in this document or media is also copyrighted material subject to the terms and conditions of the Horner Software License Agreement Information in this document is subject to change without notice and does not represent a commitment on the part of Horner Electric Inc PAGE 3 10 OCTOBER 1998 PREFACE LIMITED WARRANTY AND LIMITATION OF LIABILITY Horner Electric Inc HE warrants to the original purchaser that the RTU Modbus Network Communication Option Board manufactured by HE is free from defects in material and workmanship under normal use and service Th
4. a 17 32 ASCII Mode 17 3 3 Connection Timeout Timer 18 34 Customizing the User Configurable Protocol Frame 18 CHAPTER 4 OPERATION AND FUNCTIONALITY n 21 4 1 Drive Data Registers 21 4 1 1 21 41 2 Input Data Update Response a 21 4 1 3 Output Data Update Response r 22 41 4 Limitation on Data Registers Accessible 22 4 1 5 Input Data Transfer 22 4 1 6 Output Data Transfer Conditions cece 23 417 Data aaa asa 23 41 8 Tune Config Transfer Synchronization 24 4 1 9 Parameter Processing Error 25 4 1 10 Data Retention Timing Requirements a 25 41 11 Inaccessible Drive Parameters Keypad Only
5. 7 5 OUT 8 RTS IN 9 N C 5 CHAPTER 2 INSTALLATION 10 OCTOBER 1998 PAGE 14 HEC GV3 RTU RS 15 pin D TERM 9 RXD 10 TXD 12 4 A RXD 11 B TXD 13 Li 7 ov 7 J ov oV Figure 2 5 Two Wire RS 485 Wiring Diagram 15 10 OCTOBER 1998 CH 3 CONFIURATION CHAPTER 3 CONFIGURATION 3 1 Entering Network parameters This chapter covers configuration of the option board by entering the respective parameters through the drive s keypad For instructions on operating the drive s keypad refer to the GV3000 Installation and Operation Instruction Manual D2 3287 The drive becomes active on the RTU network after the following steps are performed 1 Connect the HEC GV3 RTU option board to the RTU network through the RS 422 serial connector 2 Apply power to the drive 3 Using the keypad access the Network ID Assignment parameter P 060 and assign a valid RTU ld to the drive limited to 1 55 4 Using the keypad access the Network Connection Type parameter 061 and select either Basic Drive Connection or Full Drive Connection 5 Using the keypad access the Comm Loss Selection parameter P 062 and select the fault action to be taken on a RTU connection time out 6 Using the keypad access the Network Frame Assignment parameter P 063 and select either the User configurable protocol frame 1 or one of the predefined
6. q 5 tae 0 6 ETWORK BOARD Figure 2 4 GV3000 Drive 15 25 HP 13 10 OCTOBER 1998 CH 2 INSTALLATION 2 3 Connecting the GV3000 Controller to an RTU Network When connecting to the RTU Modbus Communications Bus the GV3000 drive should be wired with the same cabling as other devices on the network Refer to the EIA RS 422 standard for cable and termination guidelines The option board provides an internal 120 ohm terminating resistor for the receive pair which can be strapped by shorting pins 9 and 10 on the DB 15 Only the two end point devices on the RS 422 cable should have terminators enabled Table 2 1 DB 15 Port Pin out Female Pin Tag Direction 1 N C 2 N C 3 N C 4 N C i 5 5V OUT 6 RTS OUT 7 GND 8 CTS IN 9 Terminator short 9 amp 10 10 enable 10 RXD IN 11 RXD IN 12 OUT 13 TXD OUT 14 RTS OUT 15 CTS IN Handshake and factory lines are not used for RTU communications and should not be connected An optional RS 422 to RS 232 Adapter is available from Horner Electric It receives power from pins 5 and 7 The part number is HEG93SNP232 When using this adapter the RS 232 pin out is as follows Table 2 2 DB 9 Port Pin Out Male Pin Tag Direction 1 N C 2 TD OUT 3 RD IN 4 N C 5 GND 6 N C
7. 000 CNTL REF INPUTS ACTIVE OPTION OP 2 UPDATED 1 14 TUNE CFG TUNE INPUTS ENABLE UPDATED VI CONFIG INPUTS RUNNING UPDATED Figure 4 1 Transfer Condition Logic Summary 4 18 Tune Config Transfer Synchronization Flag To allow the network master s application program to determine when tunable and configurable inputs have been updated in the drive a sync write bit Drive Control Word Reg 32 bit 15 is provided which is copied to a sync read bit Status Word Reg 0 bit 7 by the drive The drive copies the sync write bit to the sync read bit after the drive has read in and processed all tunable and or configurable input registers The Tune Cnfg input enable bit must be set 1 in order for this to happen Note that configurable type inputs are only read in by the drive while it is not running This does not affect the copying of the sync bit since tunable inputs are still transferred By toggling the sync bit in the master and by monitoring the copied value from the drive the master s application program determines when the drive has read in data This feature is provided for those applications which may require this type of synchronization It is not necessary for the master s application program to use it as it has no affect on drive operation To determine when changes to tunable and configurable data on the drive have been completed the master performs the following seq
8. drive output data is categorized as one of two types runtime signal data or tunable configuration and status data Runtime signal data includes things such as selected speed reference value sequencing status ready running etc drive fault flags terminal block digital inputs state and front panel display mode values RPM Volts Amps The information is transferred from the regulator to the data registers every speed loop scan period for the GV3000 every 5 milliseconds Tunable configuration and status data includes all other information provided by the drive which is not defined as runtime signal data This would typically include all drive parameter values When accessed via the network the data provides a complete image of how the drive is configured and operating Tunable configuration and status data are transferred from the regulator to the data registers whenever the regulator performs the processing of new tunable and configurable input parameters This occurs every 100 milliseconds 4 1 4 Limitation on Data Registers Accessible Basic Extended The data registers are divided into a Basic and Extended set The Basic set covers the first 64 data registers while the Extended set includes the Basic set plus all remaining data registers Drive parameter Network Connection Type P 061 selects the set and determines which data registers are updated or read by the regulator While configured to the Basic set the drive blocks tran
9. result in severe bodily injury or loss of life DANGER Do not install modification boards with power applied to the controller Disconnect and lock out incoming power before attempting such installation Failure to observe this precaution could result in severe bodily injury or loss of life CH 1 INTRODUCTION 10 OCTOBER 1998 PAGE 6 CHAPTER 1 INTRODUCTION 1 1 Product Description The Horner Electric RTU MODBUS Network Communications Option Board HEC GV3 RTU allows a GV3000 controller to be operated and monitored remotely via an RTU Master The option board mounts below the regulator board inside the GV3000 controller connected via a flexible ribbon cable Power for the option board comes from the GV3000 controller power supply The option board allows different levels of configuration and tuning of the GV3000 drive registers according to preference and the capability of the RTU Network master Once configured the drive can be completely controlled via the option board Reset fault code monitoring and complete control can all be accomplished over an RTU network In many applications there may be only a network interface connection hard wired emergency stop Function Loss input and three phase input and output power wiring Control and status information is passed between the drive and the network as 16bit values using RTU READ and PRESET Holding Register commands Parameters are grouped in such a manner to optimize control tu
10. transmits two stop bits RTU Odd or Even 2 stop bits Actually only transmits one stop bit The following steps are required to activate and program the User configurable protocol frame selection a Establish communication with SMARTCFG 1 Connect to a PC com port though an RS 232 to RS 422 adapter to the option board communications port 2 Apply power to the drive 3 Using the keypad access the Network Frame Assignment parameter 063 and set it to 0 4 Remove power to the drive allowing the keypad indicators to go completely out 5 Apply power to the drive and observe for the option card s MS LED to flash RED 6 Run SMARTCFG on the PC and configure the parameters Note that when the drive is power cycled with the Network Frame Assignment parameter set to zero the option board is not capable of RTU communications or drive control Setting the Network Frame Assignment parameter to zero does not affect current communications until the drive is power cycled 19 10 OCTOBER 1998 CH 3 CONFIURATION b Set parameters with SMARTCFG Use arrow keys to select option e g baud rate stop bits etc Press the Enter key after selection is made Press Space Bar key to change parameters of selection After changing the parameters Press the ESC key to return to main menu Press ESC key once more to exit software utility Horner Electric Smart Confiqurator Version 0 20 Ken Jannotta dr HE G 3 RTU Configu
11. washers provided on the right side Use the two 2 plastic rivets to fasten the left side of the board to the stand off bracket 9 Re install the regulator board keypad bracket assembly to the controller base 9 10 OCTOBER 1998 2 INSTALLATION RIBBON CONNECTOR TO REGULATOR BOARD 2000000000 wa 016 o 900000000 00000000000 l 9000000000 00000000 9 9 015 U17 59 09 0000000000 00000000 U21 oo 9 oo 00000000 0000000000 89 99 J2 U14 U18 U19 fe o 0000000000 00000000 0000000000 DOOM ESE s 5 a 2010 0116209 00000000000 5000 0000 Ga oooooon 95 Ul 80 oo Soooooon U12 d 20 uae 00856 33 go 00009900 ooooooooooo 00000000 000000000 O QO A RS 485 Port Figure 2 1 RTU Modbus Option Board CHAPTER 2 INSTALLATION 10 OCTOBER 1998
12. EFACE ama uyanta suma unu tebe fee Sea GO wi a AAR 2 LIMITED WARRANTY AND LIMITATION OF LIABILITY 3 ABOUT PROGRAMMING EXAMPLES rr 3 a aka aka a ne 4 SAFETY NOTICES be 5 CHAPTER 1 6 Tel Description 6 1 2 Additional Informations 7 2 1 konba koka aaa k pea nat ak aa aus pote konesan 8 2 1 Safety Notices Larie eee ayka alte Daha Qa uta a uhuta 8 2 2 Installingthe HEC GV3 RTU Option Board 8 23 Connecting the GV3000 Controller to RTU Network T 13 CHAPTER 3 CONFIGURATION u uu 15 31 Entering Network parameters 15 3 1 1 Network ID Assignment r 15 3 1 2 Network Connection Type r 15 3 1 3 Network Communications Comm Loss 1 a 16 3 1 4 Network Frame Assignment
13. d diagnostic LEDs to aid in troubleshooting Table 4 4 gives the possible errors error codes which the master may return for a point Table 4 5 shows the status of the option board MS and the incoming messages NS Table 4 4 RTU Modbus Response Errors Error Code Reason Invalid Function Code 1 Requested RTU function code not supported Attempt to access parameter beyond valid offset Data Address 2 or Attempt to write READ ONLY parameter Illegal Data Value 3 Attempt to read or write more than 125 parameters CHAPTER 4 OPERATION 10 OCTOBER 1998 PAGE 28 Table 4 5 Option Board LEDs MS Led Description Red Solid Factory Diagnostics mode Contact Technical Support Red Flash User configurable protocol frame program mode Green Solid Network active Green Flash Network not active connection time out timer expired NS Led Description Red Flash Data activity but invalid frame protocol or RTU checksum error Yellow Flash Valid RTU frame with non match address normal if other RTU devices communicating Green Flash Valid RTU frame addressed to this device 29 10 OCTOBER 1998 APPENDIX APPENDIX ACCESS DRIVE DATA REGISTERS A1 1 Drive Status The remote run time status of the drive is typically returned in Drive Registers 0 through 11 These values reflect the drives actual status re
14. d result in severe bodily injury or loss of life 2 2 Installing the HEC GV3 RTU Option Board Refer to Figures 2 1 2 4 1 Disconnect and lock out all incoming power to the GV3000 controller 2 Loosen the four 4 captive screws at the corners of the GV3000 controller cover and remove the cover Refer to Figure 2 2 3 Disconnect the ribbon cable that runs between the right side of the regulator board and the daughter board from the connector on the daughter board 4 If the controller is equipped with a fan disconnect the fan power leads from the connector on the power board 5 Remove the three 3 screws that fasten the stand off bracket to which the regulator board and keypad are mounted to the controller base and remove the regulator board keypad bracket assembly from the controller 6 Invert the regulator board keypad bracket assembly so that the keypad is on the bottom The ribbon cable that connects to the daughter board extends from the left of the regulator board and the ribbon cable that connects to the RTU Modbus Network Communications Option Board extend from the right of the regulator board Refer to Figure 2 1 7 Connect the ribbon cable that extends from the right side of the regulator board to the connector on the RTU Modbus Network Communication Option Board 8 Mount the RTU Modbus Network Communication Option Board to the underside of the stand off bracket Use the two 2 M3 self tapping screws and lock
15. e obligation of HE under this warranty shall be limited to the repair or exchange of any part or parts which may prove defective under normal use and service within two 2 years from the date of manufacture or eighteen 18 months from the date of installation by the original purchaser whichever occurs first such defect to be disclosed to the satisfaction of HE after examination by HE of the allegedly defective part or parts THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES AND HE NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS RTU MODBUS NETWORK COMMUNICATION OPTION BOARD THIS WARRANTY SHALL NOT APPLY TO THIS BOARD OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT NEGLIGENCE ALTERATION ABUSE OR MISUSE HE MAKES NO WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY HE THE TERM ORIGINAL PURCHASER AS USED IN THIS WARRANTY SHALL BE DEEMED TO MEAN THAT PERSON FOR WHOM RTU MODBUS NETWORK COMMUNICATION OPTION BOARD IS ORIGINALLY INSTALLED THIS WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNITED STATES In no event whether as a result of breach of contract warranty tort including negligence or otherwise shall HE or its suppliers be liable of any special consequential incidental or pena
16. ed is scaled according to those formulas presented in the GV3000 SE AC General Purpose Volts Hz and Vector Duty Drive Software Startup and Reference Manual under Speed Display Scaling P 028 A1 2 Drive Control A1 2 1 General Network run time drive control consists primarily of manipulating Drive Registers 32 33 and sometimes 34 Once in OPtion mode these parameters is used to control the drive alternately to those values input through the Control Terminal and or Keypad when the drive is LOCaL rEmote mode APPENDIX 10 OCTOBER 1998 30 1 2 2 Register 32 Drive Control Word The bits in this register are used by the drive alternately to the Discrete voltage inputs to the Control Terminal Generally asserting a bit in the Drive Control Word while under OPtion mode performs the same function asserting a control voltage on the Control Terminal while under reMote mode Exception and special conditions are listed as follows 1 Before the drive can be started with the Start bit the conditions which activate the Drive Ready bit into the Status Word Register 0 must be active 2 Start bit must make a high to low transition to start the drive Once Drive Status indicates the drive started the Start bit can be reset The drive is then stopped by releasing the Stop bit 3 Tune Cnfg input enable bit causes the drive to accept option card default or updated Tune Config parameters Setting this bit can severely alt
17. ed torque reference from the terminal block analog input and its STOP input from the terminal block STOP input All other inputs are held at the last values received from the network master 17 10 OCTOBER 1998 CH 3 CONFIURATION This allows the network master to continue controlling the drive reference with a direct wired analog output to input and to STOP the drive with a direct wired digital output to input Note that once the drive is stopped while in this mode it cannot be re started until network communications is re established or the operation control source P 000 is changed In this case the response to network communication loss is as follows A fault does not occur e Anentry is made into the drive s error log for each active to inactive transition of the network communication status e The front panel REMOTE LED blinks indication that the network is inactive e Once network communications has been re established the drive follows the reference and sequencing control inputs supplied by the network master The front panel REMOTE LED is on continuously indicating that the network is active Itis important to note that in this configuration it may not always be possible to stop the drive over the network Some form of hardwired stop must be used e g function loss input configured for IET when asserted to stop the drive 3 1 4 Network Frame Assignment RTU communications protocol supports a variety of frame p
18. er drive operation See Chapter 4 A1 2 3 Register 33 Network Speed torque Reference This register is used to control the drive s speed reference when the drive is in Option mode and the Remote Local control is in Remote mode This value is scaled such that the 0 is equal to stop and the value 4095 is equal to full speed 31 10 OCTOBER 1998 APPENDIX B APPENDIX B DEFAULT TUNE CONFIGURATION REGISTERS TheTune Config data registers not explicitly preloaded through Explicit network messages contain default values as described in Table B1 Table B1 Default Tuning Configuration Register Preload Values Register Default Load Value 32 Stop 33 0 34 0 35 0 36 0 37 20 0 38 20 0 39 5 0 40 60 0 41 100 42 0 43 1 000 44 0 45 0 46 0 47 0 48 0 49 5 0 50 0 51 0 52 1800 53 0 54 0 55 0 56 0 57 0 58 0 59 0 60 0 61 0 62 0 63 P 063
19. ers do not limit network control CHAPTER 4 OPERATION 10 OCTOBER 1998 PAGE 26 Table 4 2 Inaccessible Parameters Description Parameter Second menu enable password P 006 Terminal block digital inputs config P 007 Terminal block speed reference selection P 008 Second accel rate P 017 Second decel rate P 018 MOP acc dec rate P 023 MOP reset configuration P 024 Multispeed preset 1 P 031 Multispeed preset 2 P 032 Multispeed preset 3 P 033 Multispeed preset 4 P 034 Multispeed preset 5 P 035 Multispeed preset 6 P 036 Multispeed preset 7 P 037 Multispeed preset 8 P 038 Restore parameters defaults command P 050 Program disable password P 051 Network drop number P 060 Vector torque loop self tune enable U 008 4 1 12 Drive Ready Status Bit The Drive Ready status bit Drop_1 Reg 0 Bit 0 is used to indicate that a 0 to 1 transition on the start input starts the drive The Drive Ready bit is ON 1 when all of the following conditions are met and OFF when one or more are not met No drive faults are active Drop 1 Reg 0 Bit 2 1 Stop input is ON 1 Drop_1 Reg 32 Bit 1 1 Front panel STOP RESET button is not pressed Function loss TB input closed Drop_1 Reg 0 Bit 12 1 A download from the serial port using the CE3000 is not in progress If in the JOG mode Drop_1 Reg 0 Bit 3 1 then in addition the vector torque loop self tune enable parameter mu
20. gardless of the Control Source or the Auto Remote mode Refer to Horner Electric s Supplement SUP 0096 Table1 description column to determine the Drive Register functions Registers 0 1 and 5 are covered in more detail in this appendix a Register 0 Status Word The first half of the word provides a bit mapped run time status of the drive similar to that which is displayed by the keypad The second half of the word provides an indication of the physical inputs to the Control Terminal The drive ready status bit Status Word Reg 0 bit 0 is used to indicate that a 0 to 1 transition on the start input starts the drive The drive ready status bit is ON 1 when all of the following conditions are met and OFF 0 when one or more conditions are not met e No drive faults are active Fault Active Register 0 bit 2 Stop input is ON 1 Stop Register 32 bit 1 e Front panel STOP RESET button is not pressed e Function loss TB input closed monitored w Function Loss Register 0 bit 12 b Register 1 Selected Speed Reference This register returns the currently selected speed reference This value is scaled from 0 4095 where 4095 is the maximum allowable value i e The maximum 4095 value may correspond to 10 Volts at the Control Terminal Analog Speed Reference Input or the maximum value placed in Register 33 Register 5 RPM Display This value returns the current output frequency scaled of the motor The value return
21. gisters to the regulator every speed loop scan period for the GV3000 every 5 milliseconds or as often as it is required by the drive For example if the drive is configured to obtain its torque reference from the option pori it reads this data from the option port every torque loop control scan Tunable inputs include parameters which modify the drive s response regardless of the drive s run state Tunable data includes parameters such as accel decel rates min max limits gains or offsets etc Tunable inputs are transferred from the data register to the regulator whenever the regulator performs the processing of new tunable parameters This occurs approximately every 100 milliseconds while the drive is running or stopped Configurable inputs include parameters which alter the way that the drive operates in such a way that they cannot be modified while the drive is running Configuration data includes parameters such as reference source selection 1 configuration motor tach nameplate data etc Configurable inputs are transferred from the data registers to the regulator whenever the regulator performs processing of new configuration parameters This occurs approximately every 100 milliseconds while the drive is stopped Values sent from the network master while the drive is running are not read in and used by the drive regulator until the drive is stopped CHAPTER 4 OPERATION 10 OCTOBER 1998 PAGE 22 4 13 Output Data Update Response The
22. he first 64 drive registers The Full Drive Connection 1 allows RTU access to all drive registers see section 4 1 5 for further limitations on writes This selection becomes more prevalent when using the Tune cnfg enable bit to load configuration and tuning parameters from the RTU network The drive s network connection type is selected with the Network Connection Type parameter P O61 3 CONFIGURATION 10 OCTOBER 1998 PAGE 16 3 1 3 Network Communications Comm Loss The option board maintains a timeout timer that is reset on receiving a valid command Whenever communication is interrupted the timer times out the board immediately notifies the drive regulator of this occurrence and then waits for the next RTU command to re establish communications The drive then reacts to the loss of communications according to how the Comm Loss Selection parameter P 062 has been configured a 0 1 Fault If P 062 is equal to 0 the drive considers a Loss of Network Communication as a drive fault resulting in an stop sequence To eliminate extraneous fault conditions at power up of a drive configured for network operation the drive delays for approximately 10 seconds after power up before annunciating a fault condition A fault condition is annunciated thereafter if network communications have not been established or if network communications was established and then lost In this case the response to the network communicatio
23. he transfer of tunable and configurable register data to the drive regulator Until this bit is set ON 1 only Control Reference data registers are read in by the drive regulator This gives the master s application program direct control over when tunable and configurable parameter values are read in by the drive if at all 23 10 OCTOBER 1998 CHAPTER 4 OPERATION For example if a master loads Tune Config parameters it must first initialize the tunable and configurable parameter data through network messages to the appropriate data registers Then a network message setting the Tune Cnfg input enable bit in the Drive Control Word enables the transfer of this data to the drive s data registers Once the Tune Config register data is transferred to the drive s regulator the Tune Cnfg input enable bit must be reset to prevent regulator overhead and un expected changes in Tune Config parameters The Tune Config Update synchronization flag described in Section 4 1 8 can be used to determine when the regulator has transferred the data Those Tune Config data registers not explicitly preloaded through network messages contain default values as described in the Appendix Note that the default value is not the same as the value previously loaded by the keypad Alternately should the user prefer that inputs are set exclusively by the keypad and that the network only modifies the control reference data to the drive the master sho
24. is preset to a value determined by the current selection in the Network Frame Assignment parameter If this period is not acceptable it can be changed by modifying the Connection timeout field in the User configurable protocol frame which must be selected as the active frame The period should be set to a value larger than the expected time between incoming RTU Modbus commands The timer may be disabled by setting the period to zero See Customizing the User Configurable Protocol Frame section below 3 4 Customizing the User Configurable Protocol Frame SMARTCFG If one of the preset Network Frame Assignment P 063 selections don t meet the requirements of the network the User configurable protocol frame selection can be custom tailored with the optional configuration tool SMARTCFG An optional RS232 to RS485 converter is also required to communicate with a PC com port SMARTCFG is a Horner Electric utility that is IBM compatible and only works with Dos version 3 3 or higher The SMARTCFG utility is used to configure stop bits baud rates data types and timeouts The User configurable protocol selection can be configured to support the following Modes RTU or ASCII Baud 1200 2400 4800 9600 14 4k 19 2k 38 4k and 57 6k Parity None Odd and Even Stop bits 1 2 Connection time out 0 off 120 sec The following combinations are not supported and may cause frame errors with some RTU devices ASCII None 1 stop bit Actually
25. l damages including but not limited to loss of profit or revenues loss of use of the products or any associated equipment damage to associated equipment cost of capital cost of substitute products facilities services or replacement power down time costs or claims of original purchaser s customers for such damages To obtain warranty service return the product to your distributor with a description of the problem proof of purchase post paid insured and in a suitable package ABOUT PROGRAMMING EXAMPLES Any example programs and program segments in this manual or provided on accompanying diskettes are included solely for illustrative purposes Due to the many variables and requirements associated with any particular installation Horner Electric cannot assume responsibility or liability for actual use based on the examples and diagrams It is the sole responsibility of the system designer utilizing the RTU Modbus NETWORK COMMUNICATION OPTION BOARD to appropriately design the end system to appropriately integrate the RTU Modbus NETWORK COMMUNICATION OPTION BOARD Module and to make safety provisions for the end equipment as is usual and customary in industrial applications as defined in any codes or standards which apply Note The programming examples shown in this manual are for illustrative purposes only Proper machine operation is the sole responsibility of the system integrator PREFACE 10 OCTOBER 1998 PAGE 4 TABLE OF CONTENTS PR
26. n loss is as follows drive latches a fault condition and performs a coast stop sequence e Afault code is logged in the drive s error log and displayed on the front panel display nCL network Comm Loss e The front panel REMOTE LED blinks indicating that the network is inactive e Once network communications has been re established a drive fault reset is required to re start the drive Note A fault reset does not clear the error log b 1 Hold Last Reference If P 062 is equal to 1 the drive continues to operate using the last reference received from the network master In this case the response to network communication loss is as follows e A fault does not occur Anentry is made into the drive s error log for each active to inactive transition of the network communication status e The front panel REMOTE LED blinks indicating that the network is inactive Once network communications has been re established the drive follows the reference and sequencing control inputs supplied by the network master The front panel REMOTE LED is on continuously indicating that the network is active Itis important to note that in this configuration it may not always be possible to stop the drive over the network Some form of hardwired stop must be used e g function loss input configured for IET when asserted to stop the drive 2 Use Terminal Block Reference If P 062 is equal to 2 the drive obtains its spe
27. ne and monitor packets An RTU connection time out timer may be enabled to determine when RTU control is lost If RTU control is lost one of three different drive operation responses be selected Commonly used RTU frame protocols baud stop bits and data size mode may be selected from a list a user configurable frame protocol may be created through the optional PC configuration utility SMARTCFG a Mechanical Description The option board is a printed circuit assembly that mounts inside a GV3000 Controller The option board connects to the GV3000 Controller s regulator board via a ribbon cable A DB15 connector is used to connect the option board to a dual twisted pair RS 422 network An optional RS 232 to RS 422 converter may be used to provide an interface to an RS 232 serial connection The option board also contains 2 LEDs which provide a visual indication of the state of the option board time timer and communications activity b Electrical Description The option board contains its own microprocessor The microprocessor connects to one port of the module s dual port memory while the other port interfaces with the GV3000 s regulator The board contains a watchdog timer which is enabled when power is turned on to the Controller The microprocessor must reset the watchdog timer within a specified period or the microprocessor shuts down resulting in a F 60 code on the GV3000 controller s front panel display The option board
28. ommands required to access drive register data is either Read or Preset Holding register based on whether it is a read or write operation respectively The low level frame commands supported by the option board are listed in table 4 3 below Table 4 3 RTU Modbus Function Codes Function Code Valid Offsets Maximum Length Read Holding Registers 3 0 182 183 Preset Single Holding Register 6 0 182 1 Preset Multiple Holding Registers 16 0 182 183 Read Exception Status 7 Loopback Maintenance 8 sub commands 0 1 4 10 15 Every other 32 word region starting at offset 0 is read only and generates an error if addressed by this command A high level configuration generally only requires a PLC register address offset to access a drive s data register The master automatically determines the frame offset and commands to use based on both the PLC address and whether the operation is read or write The PLC address is based on the Modbus register addressing scheme in which addresses in the 4001 4999 40001 49999 range correspond to the PLC s analog holding registers Since the drive s registers appear to the RTU Modbus network as PLC holding registers the PLC address of a drive s register would be the drive register number plus either 4001 or 40001 depending on the PLC addressing range supported by the master 4 3 Network Diagnostics The option board provides both RTU Modbus error responses an
29. protocol frames 2 8 Selecting the User configurable protocol frame requires running an external configuration program to set the specific parameters such as baud rate parity stop and time out Note that P 061 P 062 and P 063 can also be accessed and changed via the network Serial communications can then be established with an RTU master Input and Output information can be accessed using the READ HOLDING REG and PRESET HOLDING REG RTU commands However additional requirements must be met before inputs can be transferred to the drive regulator These requirements are described in Chapter 4 3 11 Network ID Assignment RTU communication networks can support up to 246 nodes on a network However because of network hardware limitations the number of nodes is generally limited to 32 Each node on an RTU communications network must be assigned a unique ID number This ID is used by the RTU Master to route commands to the appropriate RTU device The Network ID Assignment parameter P O60 contains the ID for this option board and may be any value from 1 to 55 3 1 2 Network Connection The drive s Network Connection Type parameter defines the scope of status and control that the RTU master has with the connected drive Two types of data connections are provided Basic Drive Connection and Full Drive Connection The Basic Drive Connection 0 limits the number of control and status parameters accessible over the RTU network to t
30. provides communications through a DB 15 RS 422 communications port 7 10 OCTOBER 1998 INTRODUCTION 1 2 Additional Information The user needs to be familiar with all of the instruction manuals that describe the system configuration This may include but is not limited to the following D2 3323 GV3000 AC General Purpose Volts Hz and Vector Duty Drive Software Startup and Reference Manual Version 4 0 or later D2 3324 GV3000 AC Power Modules Hardware Reference Installation Troubleshooting 1 150 HP 380 460 VAC Version 4 0 or later CHAPTER 2 INSTALLATION 10 OCTOBER 1998 PAGE 8 CHAPTER 2 INSTALLATION 2 1 Safety Notices a DANGER Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install it Read and understand this manual in its entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life b DANGER The user is responsible for conforming to the NEC CEC and all other applicable local codes Wiring practices grounding disconnects and overcurrent protection are of particular importance Failure to observe this precaution could result in severe bodily injury or loss of life c DANGER Do not install modification boards with power applied to the controller Disconnect and lock out incoming power before attempting such installation Failure to observe this precaution coul
31. rator Core Version 1 00 19200 DATA ETU FARITY E aTOP TIMEOUT 000 ESC Figure 3 1 Example Configuration Screen smartcfg BEE Horner Electric Smart Configurator Version 0 20 Ken Jannotta Jr Parameter BAUD Value 19200 Select from 1200 2400 4800 9600 14400 19200 38400 57600 Press SPACE to toggle options ESC Back Figure 3 2 Example Configuration Screen 3 CONFIGURATION 10 OCTOBER 1998 PAGE 20 c Reset option card from Run Configurator only mode 1 Using the keypad access the Network Frame Assignment parameter P 063 and set it to 1 User Configurable Protocol Frame 2 Once the MS LED begins to flash GREEN the option board port is configured and ready to control the drive 21 10 OCTOBER 1998 CHAPTER 4 OPERATION CHAPTER 4 OPERATION AND FUNCTIONALITY 4 1 Drive Data Registers Overview 4 1 1 General The drive is monitored and controlled over the network by reading and writing through RTU Modbus commands to the drive s data registers The data registers are addressed over the network by a register number Reg and contain 16 bit values The data registers are divided into separate types according to function Generally speaking the Tune Config registers hold an image of the P xxx H xxx and U xxx parameters accessible by the drive s keypad and the Control Reference registers hold an image of the drives ph
32. rotocols However each node on the same network must be configured the same The Network Frame Assignment parameter allows the user to select either a typical pre assigned protocol or create a custom protocol configuration specific to their network The following table indicates which frame protocol is selected by the value in the Network Frame Assignment parameter P063 Table 3 1 Network Frame Assignment Selection Mode Baud Parity Stop bits Connection timeout 0 Run configurator only 1 User configurable protocol frame 2 RTU 9600 N 1 6 Sec 3 RTU 9600 O 1 6 Sec 4 RTU 9600 E 1 6 Sec 5 RTU 19 2K N 1 3 Sec 6 RTU 19 2K O 1 3 Sec 7 RTU 19 2K E 1 3 Sec 8 RTU 57 6K N 1 3 Sec Since this parameter can be modified by the keypad or the network on the fly use caution to prevent non intentional loss of communications 3 2 ASCII Mode Support Some RTU Modbus masters transport data over the network in an encoded seven bit ASCII format This ASCII mode of operation is supported but must be configured by modifying the Mode field in the User configurable protocol frame which must be selected as the active frame See Customizing the User Configurable Protocol Frame section below 3 CONFIGURATION 10 OCTOBER 1998 PAGE 18 3 3 Connection Timeout Timer Adjustment This timer is used for determining when a Loss of Network Communications occurs The connection timeout timer
33. sfer reading and writing to data registers above Register number 64 Normally networks are not used to access to data registers above register number 64 Therefore this option is especially useful in limiting the number of Tune Config parameters which are modified in the regulator when using the Tune Config option described below Since the network option board does not provide default values for those Tune Config data registers over register number 64 each Tune Config data register above that number must be initialized over the network when using the Extended set and the Tune Config option Note Use care not to inadvertently set Reg 61 since this register 061 enables the Extended set 4 1 5 Input Data Transfer Conditions The network option board must be actively communicating with a master and it must be selected as the drive s control source P 000 OP 2 in order for any inputs to be transferred from the data registers to the drive regulator Note that the keypad can still be used to change parameter values when the drive control source is the network option However any changes made via the keypad are overwritten with data register values when the next input data update occurs This needs to be kept in mind if parameter changes need to be made while the network option is the control source for the drive In addition a network controlled Tune Cnfg input enable bit Drive Control Word Reg 32 bit 14 is provided to enable t
34. st be OFF U 008 OFF 4 2 Network Access to Drive Registers The drive registers accessible over the network are summarized in SUP0096 Supplement for Reliance GV3000 Drive Registers which is provided as part of this document Based on the information provided in this supplement and section 4 1 the user must decide which of these drive registers to access over the network Note that when the drive Network Connection Type parameter P 061 is configured for Basic Drive Connection ONLY the first 64 drive registers contain valid data Note Always verify that ALL tune config parameters in the current Drive Connection set have been initialized to a sane value before writing the Tune Config inputs enabled bit in the first drive command register 27 10 OCTOBER 1998 CHAPTER 4 OPERATION Configuring RTU Modbus masters can vary in what information is required to access a selected drive register over the network While it is outside of the scope of this manual to cover configuring a master device some generalized guidelines are presented In any case the RTU Modbus master documentation should be consulted for configuration details Generally a drive register s offset is entered at the master as either a frame low level offset or a PLC high level offset A frame offset directly corresponds to the drive register number presented in SUPO096 In addition frame offset configuration generally also requires a command number The c
35. the drive every 5 milliseconds Special cases to this rule are the start input and the error log clear command The start input requires a 0 to 1 transition in order to start the drive The start input from the network may be delayed by the drive for up to 100 milliseconds This is done to synchronize a drive start to the processing of new configurable data In order for the network master to assure this 0 to 1 transition is detected by the drive the network master must maintain both the 0 and 1 states for at least 100 milliseconds each Values which are maintained for less time may not be detected by the drive The error log clear command bit is processed every 100 milliseconds even though it is defined as control reference data A 0 to 1 transition must be detected by the drive after the network is active and the control source has been selected to be the network option for the error log to be cleared In order for the network master to assure this 0 to 1 transition is detected by the drive it must maintain both the 0 and 1 states for a least 100 milliseconds each 4 1 11 Inaccessible Drive Parameters Keypad Only parameters There are a few GV3000 parameters which are not accessible through drive data registers and therefore are not accessible through the network Table 4 2 is a list of parameters that are inaccessible Because most of the inaccessible parameters are related to local drive control functions only the inability to access the paramet
36. uence Modify the tunable and or configurable register data in the appropriate network register s Set the Tune Cnfg input enable flag if not already set Toggle the network synchronization flag Monitor the loopbacked copy read register of the network synchronization flag until it equals the value written in step 3 POI 25 10 OCTOBER 1998 CHAPTER 4 OPERATION 4 1 9 Parameter Processing Error Flag A Parameter Processing Error Flag Fault Log Entries Reg 14 bit 8 is provided to allow the network master to determine whether any parameter values are unacceptable to the drive If this flag is set 1 then one or more data register values transferred to the drive were rejected If this flag is not set 0 then all data register values sent to the drive were accepted Note that the tune config inputs enable bit must be set 1 before the drive can read in and consequently process any Tune Config parameters The parameter processing error flag is updated approximately every 100 milliseconds 4 1 10 Data Retention Timing Requirements All tunable and configurable drive input register values must be maintained by the network master s application program for at least 100 milliseconds to assure that they are seen by the drive This is particularly relevant for data which is transition detected by the drive Control reference data types generally do not have this 100 millisecond requirement since they are scanned by
37. uld not set the Tune Cnfg input enable bit The drive is then configured locally but start stop reset and reference are sent from the network master Note The user needs to exercise caution to prevent the unintentional setting of the Tune Cnig input enable bit Reg 32 bit 14 This could cause the drive to transfer un initialized tune config data from the network option card to the drive which could radically change the operation of the drive 4 1 6 Output Data Transfer Conditions All regulator output data is transferred to the data registers continuously The network does not have to be active and the network option does not have to be selected as the drive control source P 000 No output enable control bit is necessary 4 1 7 Data Transfer Summary Table 4 1 summarizes the response times to the different drive data types described earlier in this Sections 4 1 2 4 1 3 and 4 1 6 Table 4 1 Transfer between Data Registers and the Drive Regulator Direction Category Conditions Rate Input to drive Control Reference drive running or stopped 5ms Tunable drive running or stopped 100ms Configurable Drive stopped 100ms Output from drive Runtime Always 5ms Tunable 8 Always 100ms CHAPTER 4 OPERATION 10 OCTOBER 1998 PAGE 24 Figure 4 1 summarizes the conditions which effect transfer of input and output register data to the drive s regulator OUTPUTS UPDATED NETWORK P
38. ysical inputs start stop speed ref etc When the drive is configured for network control and other certain conditions are met the drive registers accessed by the network option card are selected as an alternate source for controlling the drive as opposed to the keypad and or physical input Network data written to the drive s data registers is buffered before it is transferred to the drive s internal regulator In order to minimize regulator board CPU loading the rate of transfer of register data to the drive regulator varies for different data register types Additionally some register data transfer are blocked until additional conditions are met The sections that follow describe each data type for input and output register data along with the drive s response and conditions for acceptance of transfer The presented response times do not include network transfer times The drive data registers which may be read or modified are listed in a table in Horner Electric s Supplement SUP 0096 The table lists the register number type access and description for each register 4 1 2 Input Data Update Response The drive s input data is categorized as one of three types control reference tunable or configurable Control reference inputs include data which require fast update rates This includes data such as sequencing inputs start stop run jog fwd rev etc and speed torque reference Control reference inputs are transferred from the data re
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