ACS 160 Installation and Start-up Guide RS485 and RS232 Adapter Module CFB-RS
RS485 and RS232 Adapter Module CFB-RS Installation and Start-up Guide 3BFE 64390431 R0125 EN EFFECTIVE: 23.3.
Safety Instructions Overview This chapter states the safety instructions that must be followed when installing and operating the RS485/RS232 adapter. If neglected, physical injury and death may follow, or damage may occur to the frequency converter, the motor and driven equipment. The material in this chapter must be studied before attempting any work on, or with, the unit.
Safety Instructions ii RS485 and RS232 Adapter Installation and Start-up Guide
Table of Contents Safety Instructions Overview ...................................................................................................... i Warnings ...................................................................................................... i Chapter 1 –Introduction Overview .................................................................................................. 1-1 Delivery Check .........................................................................................
References............................................................................................... 4-8 Actual Values ......................................................................................... 4-11 Fault and Alarm Status .......................................................................... 4-13 Chapter 5 – Fault Tracing Appendix A – Parameter Scaling Effect of Resolution.................................................................................. A-1 Signed Values ............
Chapter 1 –Introduction Overview The RS485 and RS232 adapter is used for connecting the ACS 160 frequency converter to a serial Modbus (RS232 or RS485) network. The adapter is IP65 protected for use in demanding environmental conditions. Delivery Check The option package includes: • RS485/RS232 Adapter • Installation and Start-up Guide for RS485 and RS232 Adapter • Two M16 x 1,5 cable glands with O-ring.
Chapter 1 –Introduction Appendix A– Parameter Scaling describes the scaling when parameters are accessed through the Modbus network. Appendix B– Technical data of the module. Appendix C– Ambient conditions. Conventions Used in This Guide This manual uses some terms and conventions which might not be known to every user of this manual. Some of these terms are described below.
Chapter 2 – Installation This chapter contains instructions for setting up the RS485/RS232 adapter. WARNING! Verify that the ACS 160 is not powered before starting the installation. Follow the safety instructions given in this Guide and in the ACS 160 User’s Manual.
Chapter 2 – Installation Mounting The CFB-RS can be mounted onto the ACS 160 drive with two screws as shown in the ACS 160 User's Manual. This also provides the earthing of the module housing. The CFB-RS uses the control panel connector of the drive. The CFB-RS is powered through this connector. The CFB-RS provides two cable entries for the incoming and outgoing bus cables. The cables are connected to a detachable terminal header.
Chapter 2 – Installation Connectors and Switches The adapter operates either in RS232 mode or RS485 mode. The mode can be selected with a jumper. By default, the adapter operates in RS485 mode at a communication speed of 9600 bps (bits per second). RS485 terminal X1 RS232 terminal X4 1 2 3 45 RS323/RS485 mode selection jumper S3 RS485 bus termination switch S1 1 2 3 45 RS485 terminal X2 Communication speed setting DIP switch S2 LEDs: TxD RxD Power Figure 2-2 Connectors and switches.
Chapter 2 – Installation Selecting the Communication Speed Communication speed is selected by DIP switch S2 and by parameter 5201 COMM SPEED. The factory setting for the communication speed is 9600 bps (bits per second). Communication speed setting using DIP switch S2 is needed only when the adapter operates in RS485 mode.
Chapter 2 – Installation Selecting RS485 or RS232 Mode The adapter operates either in RS232 mode or in RS485 mode, selectable by a jumper. As a factory setting, the adapter operates in RS485 mode. Jumper S3 Mode RS485 1 S3 RS232 2 Figure 2-4 Selecting the operating mode. RS485 Bus Termination The RS485 bus must be terminated using 120 9 resistors at both ends of the network. The adapter has built-in termination resistors that can be enabled by the bus termination switch S1.
Chapter 2 – Installation Installation to RS485 Bus 1 Make sure power is not connected to the ACS 160. 2 Set the adapter switches: • Confirm that the operation mode is RS485 (jumper S3) • Set communication speed of the adapter with DIP switch S2 • If the termination is not needed, use switch S1 to disable it. 3 Mount the adapter on the side of the ACS 160. Leave the drive connection cable disconnected. 4 Wire the adapter to the RS485 network (X1 and X2). 5 Connect the control panel to the drive.
Chapter 2 – Installation Table 2-1 RS485 connection terminals. Terminals X1 and X2 are connected in parallel. X1, X2 1 2 C 3 4 5 A B Shield Description No connection Common. Connected to ACS 160 chassis through 100 9 impedance Data negative Data positive Cable shield RS485 terminal X1 RS485 terminal X2 Figure 2-7 RS485 connection terminals X1 and X2.
Chapter 2 – Installation Installation to RS232 Bus 1 Make sure power is not connected to the ACS 160. 2 Confirm that the operation mode is RS232 (jumper S3). 3 Mount the adapter on the side of the ACS 160. 4 Connect the control panel to the drive.* 5 Connect power to ACS 160. * 6 Set up communication: Station number, communication speed of the drive and parity. Refer to Chapter 3 – Programming. * 7 Set up other drive parameters as needed. Refer to ACS 160 User’s Manual and Chapter 3 of this manual.
Chapter 2 – Installation Wiring RS232 bus is a point-to-point type bus. Typical usage is to temporarily connect the drive into the serial port of a PC. Cover of the adapter module can not be closed when RS232 connector is used. The maximum RS232 cable length is 3 meters. The RS232 cable is not included in the delivery. PC ACS 160 Serial Port Max Cable length 3 m Figure 2-8 RS232 wiring.
Chapter 2 – Installation X4 5 4 9 3 8 2 7 X4 1 6 Description 1 NC 2 TxD 3 RxD 4 DTR 5 SGND 6 DSR 7 RTS 8 CTS 9 NC Figure 2-9 RS232 signals. DTR and DSR as well as RTS and CTS signals are internally connected. The RS232 cable should not have TxD and RxD signals connected across.
Chapter 2 – Installation Earthing and Termination RS485 Bus The RS485 network should not be directly earthed at any point. All the devices on the network should be well earthed using their corresponding earthing terminals. As always, the earthing wires should not form any closed loops, and all the devices should be earthed to a common earth. The RS485 network must be terminated using 120 9 resistors at both ends of the network as shown in Figure 2-10. These resistors are already resident on the adapter.
Chapter 2 – Installation 2-12 RS485 and RS232 Adapter Installation and Start-up Guide
Chapter 3 – Programming This chapter describes how to program the ACS 160 drive for Modbus communication.The reader should be already familiar with programming the drive parameters using the control panel, and the way the parameters are arranged in groups. For details, see the ACS 160 User’s Manual. General When power is connected, the ACS 160 will automatically check for the presence of the panel.
Chapter 3 – Programming Communication Settings The configuration information is in Group 52. The contents of this group are shown in Table 3-1 below. Table 3-1 Communication parameters. Code Name Group 52 SERIAL COMM 5201 STATION NUMBER 5202 COMM SPEED 5203 5204 5205 3-2 PARITY COMM FAULT TIME COMM FAULT FUNC Range 1 - 247 3 = 300 bps 6 = 600 bps 12 = 1200 bps 24 = 2400 bps 48 = 4800 bps 96 = 9600 bps 192 = 19200 bps 0-2 0.1 - 60.0 s 0-3 Default User 1 96 (9600 bps) 0 (NONE) 1.
Chapter 3 – Programming Code Name 5201 STATION NUMBER Sets the slave number for the ACS 160 in Modbus network. Range: 1 - 247 Note! Modifications take effect only on the next power up. 5202 COMM SPEED Defines the communication speed of the ACS 160 in bits per second (bps). 3 = 300 bps 48 = 4800 bps 6 = 600 bps 96 = 9600 bps 12 = 1200 bps 192 = 19200 bps 24 = 2400 bps Note! Modifications take effect only on the next power-up. 5203 PARITY Defines the parity to be used in Modbus communication.
Chapter 3 – Programming Code Name 5205 COMM FAULT FUNC Operation in case the communication with the master device is lost. The time limit for communication loss detection is set by parameter 5204 COMM FAULT TIME. 0 = NOT SEL Communication loss is not detected. 1 = FAULT A fault indication is shown on the control panel display and included in the Status Word. The ACS 160 coasts to stop. 2 = CONST SPEED 7 A warning indication is shown on the control panel display and included in the Status Word.
Chapter 3 – Programming Control Locations The ACS 160 drive can receive control signals from multiple sources (such as the digital and analogue inputs, the control panel, and a fieldbus adapter). The user can separately determine the source for each type of control information. Especially refer to parameter groups 10, 11 and 16 in the ACS 160 User’s Manual for information on the selection parameters.
Chapter 3 – Programming Diagnostic Counters Diagnostic counters can be used for debugging the Modbus system. Counters will roll over from 65535 to 0. The counter values are stored to permanent memory when power is disconnected. Counters can be reset from the control panel by pressing the UP and DOWN buttons simultaneously when in parameter set mode, or by setting them to zero via the serial communication channel.
Chapter 3 – Programming Code Description 5206 BAD MESSAGES This diagnostics counter increases by one every time the ACS 160 finds any kind of communication error. During normal operation, this counter hardly ever increases. 5207 GOOD MESSAGES This diagnostics counter increases by one every time a valid Modbus message has been received by the ACS 160. During normal operation, this counter increases constantly. 5208 BUFFER OVERRUNS The longest possible message length for the ACS 160 is 32 bytes.
Chapter 3 – Programming Code Description 5212 BUSY ERRORS In Modbus network, only one device can transmit at any given time. This diagnostic counter increases by one every time the ACS 160 receives a character from the bus while it is still processing the previous message. 5213 SER FAULT MEM 1 Last Modbus exception code sent. Refer to "Exception Codes" on page 4-3. 5214 SER FAULT MEM 2 Previous Modbus exception code sent. 5215 SER FAULT MEM 3 Oldest Modbus exception code sent.
Chapter 4 – Communication This chapter describes the Modbus communication on ACS 160 drives. Introduction to Modbus Modbus is a serial, asynchronous protocol. The Modbus protocol does not specify the physical interface. Typical physical interfaces are RS232 and RS485, both of which are supported by the adapter. Modbus is designed for integration with Modicon PLCs or other automation devices, and the services closely correspond to the PLC architecture.
Chapter 4 – Communication Register Mapping The drive parameters are mapped to the 4xxxx area so that: • 40001 – 40099 are reserved for drive control registers • 40101 – 40199 is reserved for the actual values (parameter group 1) • 40201 – 40299 is reserved for parameter group 2 • 40301 – 40399 is reserved for fault and alarm information • … other parameter groups • 49901 – 49999 is reserved for the start-up data In this mapping, the thousands and hundreds correspond to the group number, while the tens and
Chapter 4 – Communication The register addresses between the groups are invalid. No reads or writes are allowed for these addresses. If there is an attempt to read or write outside the parameter addresses, the Modbus interface will return an exception code to the controller. Exception Codes The ACS 160 supports the standard Modbus exception codes. These are shown in Table 4-2. Table 4-2 Exception codes.
Chapter 4 – Communication Function Codes The ACS 160 supports the Modbus function codes given in Table 4-3. If any other function codes are used ACS 160 returns an exception response with error code 01 (illegal function). Table 4-3 Function codes.
Chapter 4 – Communication Table 4-4 The Control Word. See also the State machine in Figure 4-1. Bit Value Description Enter READY TO OPERATE Emergency OFF. Ramp to stop according to parameter 2203 DECELER TIME 1. Enter OFF1 ACTIVE; proceed to READY TO SWITCH ON unless other interlocks (OFF2, OFF3) are active. Continue operation (OFF2 inactive) 1 1 Emergency OFF, coast to stop. 0 Enter OFF2 ACTIVE; proceed to SWITCH-ON INHIBITED. Continue operation (OFF3 inactive) 2 1 Emergency stop.
Chapter 4 – Communication Example on Using the Control Word The following example shows how to use the Control Word to start the drive. When the power is connected for the first time, the state of the drive (see the state machine in Figure 4-1) is NOT READY TO SWITCH ON. Control Word is used to step through the state machine states until OPERATING state is reached, meaning that the drive is running and follows the given reference. Table 4-5 Using the Control Word.
Chapter 4 – Communication Table 4-6 The Status Word Bit Value 0 7 1 0 1 0 1 0 0-1 0 1 0 1 0 1 0 1 8 0 1 1 2 3 4 5 6 0 9 10 11 12 13 to 15 1 0 1 0 1 0 1 0 Description ready to switch on not ready to switch on ready to operate off1 active operation enabled Not ready (OPERATION INHIBITED) fault No fault OFF2 inactive OFF2 ACTIVE OFF3 inactive OFF3 ACTIVE switch-on inhibited Alarm is active. See Diagnostics section for a list of relevant alarms. No alarm OPERATING.
Chapter 4 – Communication References References are 16-bit words comprising a sign bit and a 15-bit integer. A negative reference (indicating reversed direction of rotation) is formed by calculating the two’s complement from the corresponding positive reference value. Reference 1 Holding Register: 40002 Reference 1 can be used as the frequency reference REF1 for the ACS 160. The signal source of external reference 1 (REF1) must be set to COMM and external control location 1 (EXT1) must be activated.
Chapter 4 – Communication Fieldbus Reference Scaling Fieldbus references are scaled as follows: Reference 1: 20000 EXT REF1 MAX (Hz, parameter 1105). Scaling Parameter 1104 EXT REF1 MIN is not used. Reference 2: 10000 EXT REF2 MAX (%, parameter 1108). Scaling Parameter 1107 EXT REF2 MIN is not used. Fieldbus Reference Fieldbus reference is selected by setting a reference selection parameter – 1103 EXT REF1 SELECT or 1106 EXT REF2 SELECT – to COMM, COMM+AI1 or COMM*AI1.
Chapter 4 – Communication Example of the effect of AI1 value on fieldbus reference. Assume that 2008 MAXIMUM FREQ = 50 Hz Assume that fieldbus reference 1 is 5000 (corresponding to 25 % of full scale) and voltage at AI1 is 3 V (corresponding to 30 % of full scale). 1. If setting COMM+AI1 is used, then corrected fieldbus reference is 25 % + 30 % - 50 % = 5 % or 2.5 Hz. 2. If setting COMM*AI1 is used, then corrected fieldbus reference is 25 % * 30 % / 50 % = 15 % or 7.5 Hz.
Chapter 4 – Communication Actual Values Actual values are read-only values containing information on the operation of the drive. Actual values are 16-bit words containing sign bit and a 15-bit integer. A negative value is given as two’s complement of the corresponding positive value. Actual Value 1 Holding Register: 40005 Actual output frequency. Scaling: 5000 50 Hz. Actual Value 2 Holding Register: 40006 Actual output current. Scaling: 10 1 A.
Chapter 4 – Communication From any state From any state Emergency Stop OFF3 (CW Bit2=0) (SW Bit5=0) From any state Emergency Off OFF2 (CW Bit1=0) OFF2 ACTIVE OFF3 ACTIVE (SW Bit4=0) Fault (SW Bit3=1) FAULT (CW Bit7=1)* f=0 / I=0 From any state OFF1 (CW Bit0=0) (SW Bit1=0) OFF1 ACTIVE SWITCH-ON INHIBITED MAINS OFF Power ON f=0 / I=0 A C D NOT READY TO SWITCH ON (CW Bit3=0) (SW Bit2=0) (SW Bit6=1) (CW Bit0=0) (SW Bit0=0) (CW=xxxx xxxx xxxx x110) OPERATION INHIBITED READY TO SWITCH O
Chapter 4 – Communication Fault and Alarm Status The ACS 160 provides fault and alarm status words for the external control system. These data words are accessible only through the serial communication link but not from the control panel. Fault and alarm status words are located in parameter group 3. The group also contains copies of the Control Word and Status Word. Group 3 parameters are of read-only type; however, both alarm words can be reset by writing a zero to them.
Chapter 4 – Communication Table 4-9 Bit descriptions for fault words 1 and 2. See also the Diagnostics section in the ACS 160 User’s Manual for more information about faults and fault codes.
Chapter 4 – Communication Table 4-10 Bit descriptions for alarm words 1 and 2. See also the Diagnostics section for more information about alarms and alarm codes. . Bit # Alarm Word 1 Alarm Word 2 0 1 2 3 4 5 6 7 8 9 10 11 Overload alarm Autorest alarm PID sleep alarm Autochange alarm. Reserved Interlock alarm.
Chapter 4 – Communication 4-16 RS485 and RS232 Adapter Installation and Start-up Guide
Chapter 5 – Fault Tracing This chapter gives step-by-step diagnostics information for finding out the causes and corrections to the most common problems with the adapter. Power LED of the adapter is illuminated, but Receive (RxD) and Transmit (TxD) LEDs are not blinking • The master device is not transmitting. • The cable is not correctly connected to connector X1/ X2 (in RS485 mode) or X4 (in RS232 mode). • Operation mode (RS485 or RS232) of the adapter is not correct: Check jumper S3.
Chapter 5 – Fault Tracing Receive and Transmit LEDs are blinking, but the responses ACS 160 sends are not intelligible • DIP switch S2 and parameter 5202 COMM SPEED do not have the same speed setting. • Ambient noise level is too high. The control panel is not operating and panel display blinks • Panel is not properly connected to the drive. • The drive is using different communication settings from the panel: Connect the panel and then turn power off and then on again.
Appendix A – Parameter Scaling This chapter is intended for people who are using the drive data through the Modbus connection, and need to know in what units the data is available for reading and writing. Effect of Resolution Parameter values are read and written through serial communication using integer values. When the given parameter resolution is 0.1, desired value must be multiplied by 10 to produce the integer value. For example, to set parameter 2202 ACCELER TIME 1 (resolution 0.
Appendix A – Parameter Scaling A-2 RS485 and RS232 Installation and Start-up Guide
Appendix B– Technical Data RS-485 Link Compatible devices: All devices compatible with Modbus protocol Size of the link: 247 stations including repeaters (31 stations and 1 repeater per segment) Medium: Shielded, twisted pair RS-485 cable (Belden 9841 or equivalent) Termination: Built in CFB-RS module Maximum bus length: 1200 m Topology: Multi-drop Serial communication type: Asynchronous, half duplex Transfer rate: 300 bit/s, 600 bit/s, 1200 bit/s, 2400 bit/s, 4800 bit/s, 9600 bit/s, 19200 bit/s.
Appendix B– Technical Data X1, X2 1 2 3 4 5 C A B Shield Description No connection Common Data negative Data positive Cable shield General: Complies with EMC standards EN50081-1 and EN50082-2 B-2 RS485 and RS232 Installation and Start-up Guide
Appendix C– Ambient Conditions Operation The following conditions apply to stationary use of the module. Installation Site Altitude: 0 to 2000 m above sea level. If the installation site is higher than 2000 m above sea level, please contact your local ABB representative for further information.
Appendix C– Ambient Conditions C-2 RS485 and RS232 Installation and Start-up Guide
EFFECTIVE: 23.3.2001 3BFE 64390431 R0125 EN ABB Industry Oy P.O.
