Toshiba Network Card Pbdp 110 User Manual

ASD INTERFACE SERIES

ICC

INDUSTRIAL CONTROL COMMUNICATIONS, INC.

PBDP-110

PROFIBUS-DP COMMUNICATIONS INTERFACE

FOR TOSHIBA ADJUSTABLE SPEED DRIVES

July 2004

ICC #10407-1.100-000

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PBDP-110 Profibus-DP Interface User's Manual

Part Number 10407-1.100-000

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.

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Usage Precautions

Operating Environment

•

Please use the PBDP-110 only when the ambient temperature of the

environment into which the unit is installed is within the following

specified temperature limits:

Operation: -10 ∼ +50°C (+14 ∼ +122°F)

Storage:

-40 ∼ +85°C (-40 ∼ +185°F)

•

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.

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 noise-

emitting 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 PBDP-110 terminals to

either the ASD’s E/GND terminals, the motor, or to any other power

ground.

•

When making common serial connections between the PBDP-110 and

ASDs, do not use cables that exceed 5 meters in length.

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 PBDP-110 derives its control power from the drive

connected to Channel A, removing power from that drive will also

cause the PBDP-110 to lose power, even if power is still applied to the

drive connected to Channel B.

•

When only 1 drive is connected to the PBDP-110, it must be

connected to Channel A.

For further drive-specific precaution, safety and installation

information, please refer to the appropriate documentation supplied

with your drive.

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TABLE OF CONTENTS

Mechanical Diagrams..................................................................5

Enclosure..............................................................................................5

Mounting Clip........................................................................................6

External Interface..................................................................................7

1.1

1.2

1.3

Feature Summary.........................................................................8

Installing the Interface...............................................................12

Installation for G7 ASDs......................................................................12

Installation for S7, S9, S11, A7 and VF-nC1 ASDs.............................14

3.1

3.2

Grounding ..................................................................................16

Environmental Specifications ..................................................16

Maintenance and Inspection ....................................................17

Storage and Warranty ...............................................................18

Storage ...............................................................................................18

Warranty .............................................................................................18

7.1

7.2

Selecting the Profibus Network Address ................................19

Exchanged Data Structures......................................................21

Output (Control) Data Format .............................................................21

Input (Status) Data Format .................................................................24

Diagnostics .........................................................................................28

9.1

9.2

9.3

10. Parameter Register Access ......................................................29

10.1

10.2

10.3

10.4

Parameter Number / Action Output Words .........................................29

Parameter Number / Action Input Words............................................30

Parameter Access Procedure.............................................................31

11. Parameter Registers..................................................................33

12. MMI Port Use / GSD Files..........................................................34

13. Notes...........................................................................................35

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1. Mechanical Diagrams

1.1 Enclosure

Figure 1: Enclosure Dimensions (units are inches)

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1.2 Mounting Clip

Figure 2: Mounting Clip Dimensions (units are inches)

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1.3 External Interface

MMI port

Address selection

DIP switches

Data_Exchange

LED

Profibus

network

connector

SHIELD grounding terminal

(refer to Section 4)

Drive “A” connector

Drive “B” Connector

Note that for clarity the above diagram shows the PBDP-110 unit removed

from its case. However, it is not necessary to remove the unit from its case in

order to install or configure the PBDP-110.

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2. Feature Summary

Protocol

Profibus DP (Decentralized Periphery) as specified in European standard EN

50170. The PBDP-110 can also co-exist simultaneously on networks using

Profibus-FMS.

Network Baud Rates

Supports all Profibus baud rates from 9.6kbaud to 12Mbaud. The network

baud rate is automatically detected and continuously monitored during

operation; no parameter settings are necessary.

Drive Connections

The PBDP-110 provides support for simultaneous connection of two Toshiba

7-series, 9-series, 11-series or VF-nC1 ASDs via the drives’ common serial

(aka logic level) communication ports. Both drives share a common Profibus

station address. By supporting 2 drives per interface, the maximum number of

drives that can be connected to 1 Profibus network segment without requiring

repeaters increases from 31 (31 drives + 1 master) to 62 (31 PBDP-110 units +

1 master).

Power Supply

Self-contained. Powered directly from the drive connected to the Channel A

communications port. No external power supply devices or connections are

required.

Isolation

The PBDP-110 has 3 separate isolated circuitry sections. Each drive is fully

optically isolated from each other, and both drives are optically isolated from

the Profibus network. By using optically isolated connections to the drives and

the Profibus network, grounding differential problems are eliminated and noise

immunity characteristics are greatly improved.

Global Control Functions

•

Freeze mode:

Sync mode:

Clear_Data:

Input (monitor) data values are held constant within the

PBDP-110 until the next “freeze” command or an

“unfreeze” command is received. Used primarily for

synchronized monitoring of multiple Profibus nodes.

Output (control) data values are held constant within the

PBDP-110 until the next “sync” command or an “unsync”

command is received. Used primarily for synchronized

control of multiple Profibus nodes.

All output (control) data values are cleared to “0”.

Drive AutoScan Algorithm

Connections to the drives are automatically established and continuously

monitored. No drive configuration needs to be performed to connect the

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PBDP-110 and communicate via the Profibus network. Just plug it in – it’s that

simple.

Network Watchdog

A network watchdog function is always operating within the PBDP-110. If the

watchdog is activated at network commissioning, then in the event of a

disconnection from the Profibus network or loss of the network master, the

PBDP-110 can automatically switch any attached drives over to local control.

Indicators

•

One green LED is provided to indicate when the PBDP-110 has achieved

the DATA_EXCHANGE state with the Profibus network master. This

serves as a convenient indicator that the Profibus master and PBDP-110

are configured properly and are exchanging data.

One green LED on the MMI interface port. The context is application-

specific, but under normal operation blinks at a 0.5Hz rate as a “heartbeat”

indicator. Also indicates data transfer when used with the Flashloader

programming utility.

One green LED on each of the Channel A and Channel B drive

connectors, which indicate that the port is receiving power from the

corresponding drive.

Profibus Network Connector

The network interface is a standard DB9 female connector with the following

signals provided:

Number

Function

In/Out

Profibus network “B” (positive) data line

In/out

Out

RTS signal – direction control for fiber optic network

interface

DGND – power supply ground internally connected to

the interface board’s isolated ground

VP – power supply +5v internally connected to the

interface board’s isolated P5.

Profibus network “A” (negative) data line

In/out

RTS signal ground reference – internally connected to

the interface board’s isolated ground

1, 2, 7

No connection

In addition to the above signals, the metallic housing of the DB9 connector is

connected to the shield section of the interface board. The shield section is

attached to the metal ground terminal on the bottom of the unit, where a

ground wire can be attached to connect the Profibus network cable shield to

ground. Refer to section 4 of this document for more information related to

grounding.

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Drive Network Connectors

TTL-level. Uses standard RJ-45 style 8-pin modular connectors. Any

standard category-5 Ethernet cable (found in most electronics stores) 5 meters

or less in length can be used to connect the PBDP-110 to the drives.

MMI Port Connector

RS232-level. Use the DB9-to-RJ-45 cable supplied with the PBDP-110 kit to

interface with the unit via the Flashloader programming utility (refer to section

12).

Input/Output Data

The PBDP-110 presents a modular interface, supporting four different modules

depending on the number of drives connected to the unit and the desired data

sizes.

If the PBDP-110 is configured for one drive (the Channel A drive) with standard

data access, the interface’s cyclic data sizes are fixed at 16 bytes of output

(control) data configured as four 32-bit words, and 24 bytes of input (status)

data configured as six 32-bit words.

If the PBDP-110 is configured for both drives (Channels A and B) with

standard data access, the interface’s cyclic data sizes are fixed at 32 bytes of

output (control) data configured as eight 32-bit words, and 48 bytes of input

(status) data configured as twelve 32-bit words.

If the PBDP-110 is configured for one drive (the Channel A drive) with compact

data access, the interface’s cyclic data sizes are fixed at 4 bytes of output

(control) data configured as two 16-bit words, and 8 bytes of input (status) data

configured as four 16-bit words.

If the PBDP-110 is configured for both drives (Channels A and B) with compact

data access, the interface’s cyclic data sizes are fixed at 8 bytes of output

(control) data configured as four 16-bit words, and 16 bytes of input (status)

data configured as eight 16-bit words.

Via these data structures, any data item (commands, monitor data and

parameters) available in the drive can be accessed. For detailed explanations

of the format and usage of this data, refer to sections 9 and 10 of this

document.

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

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1.2 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.

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3. Installing the Interface

The PBDP-110 connects to each drive via the drive’s common serial (logic

level) communication port, typically located on either the main drive control

board (G7, S11), 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 PBDP-110

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 PBDP-110, 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.

Installation of the PBDP-110 should only be performed by a qualified

technician familiar with the maintenance and operation of the connected

drives. To install the PBDP-110, complete the steps outlined in the following

sections related to your specific drive.

3.1 Installation for G7 ASDs

CAUTION! Verify that all input power sources to the drives to

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

DANGER!

Wait at least 5 minutes for the drive’s

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.

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

(refer to page 10 for more information).

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

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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

Channel A of the interface with the communication cable (communication

cable is not included with the interface 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 another drive to Channel B if desired.

10. Connect the Profibus network cable to the DB9 connector marked

“Network” on the PBDP-110. If a ground cable is going to be used, attach

the ground cable to the terminal marked “Shield GND” on the bottom side

of the PBDP-110 enclosure (refer to section 4). Refer to the Profibus

Specification for detailed network wiring guidelines. Ensure that the

Profibus network cable is tightly screwed onto the DB9 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 network cables have

sufficient clearance from drives, motors, or power-carrying electrical

wiring.

12. Configure the Profibus slave address via the DIP switches on the front of

the interface (refer to section 8).

13. 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

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remove all power from the drives. Then, verify all connections. Contact

ICC or your local Toshiba representative for assistance if the problem

persists.

3.2 Installation for S7, S9, S11, A7 and VF-nC1 ASDs

CAUTION! Verify that all input power sources to the drives to

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

DANGER!

Wait at least 5 minutes for the drive’s

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.

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

(refer to page 10 for more information).

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

(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.

5. Connect the drive’s common serial communication port to Channel A of

the interface with the communication cable (communication cable is not

included with the interface 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.

6. Repeat steps 1-5 to connect another drive to Channel B if desired.

7. Connect the Profibus network cable to the DB9 connector marked