SAFphire Application Notes

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Table of Contents INTRODUCTION TO SAFPHIRE APPLICATION NOTES...5 Assumptions...5 SAFPHIRE RS232 COMMUNICATIONS OVERVIEW...5 Supported Protocols...5 Typical Configurations...5 Programming...6 SAFPHIRE ETHERNET COMMUNICATIONS...8 Programming / Annunciating...8 Rack to Rack Communications...13 SBL Programming...14 SAFPHIRE TO ALLEN-BRADLEY PLC COMMUNICATIONS USING DF1..16 SBL Configuration...16 PLC Configuration -SLC Family...19 PLC Configuration -PLC 5 Family...22 Compatible Devices...25 Connections...25 SAFPHIRE TO MODICON PLC COMMUNICATIONS USING MODBUS...26 SBL Configuration...26 PLC Configuration...28 Compatible Devices...29 Connections...29 SAFPHIRE TO MAN-MACHINE-INTERFACE COMMUNICATIONS USING MODBUS...30 SBL Configuration...30 MMI Configuration...32 Compatible Devices...33 Connections...33 SAF TO ABB DRIVES COMMUNICATIONS USING DDCS (POINT TO POINT CONNECTION)...34 Implementation...35 Connections...35 Page 3

SBL Block Programming...36 SAFphire to DCS500B drive...38 SAFphire to DCS400 drive...41 SAFphire to ACS600 release 5 Drive...43 MULTI NODE DDCS COMMUNICATIONS...45 SBL Block Programming...46 SAFPHIRE TO SAFPHIRE COMMUNICATIONS USING DDCS (POINT TO POINT)...48 Connections...49 SBL Block Programming...50 TECHNICAL SUPPORT...55 Page 4

Introduction to SAFphire Application Notes This collection of SAFphire Application Notes is designed to aid SAFphire users and SBL Programmers in the design of SAFphire systems. These App. Notes are designed to explain how to use SAFphire to accomplish a specific task. Typical App Note Topics Include: communicating between SAFphire and a specific PLC or MMI connecting SAFphire to a specific external device performing a specific software function in SBL These App Notes will show very specific examples, but can be modified to suit individual applications. Assumptions It is assumed that the reader will be familiar with SAFphire basics as well as SBL programming. This manual is designed to allow the reader to very quickly learn advanced topics after the basics have been mastered. SAFphire RS232 Communications Overview The CA418 Processor Card for SAFphire and the OEM SAFphire allow for communications using industry standard protocols without adding additional SAFphire hardware. This allows for a cost effective connection to PLC's MMI's or other compatible devices. Communications to other devices is achieved by using one of the on board serial ports of the processor card. (processor card refers to either a CA418 or to an OEM SAFphire) Because the onboard serial ports are RS232 ports, only point to point connections are supported. The actual communications supported is a subset of the full protocol. Please see the appropriate App Note for implementation details. Supported Protocols Supported protocols include: Allen-Bradley DF1 Modicon Modbus RTU Master Modicon Modbus RTU Slave Other communication networks are available for SAFphire by using the CA414 SAF-Link communications Gateway. Typical Configurations The processor card has two serial ports labeled DOWNLOAD PORT and HAND TERMINAL PORT. The DOWNLOAD PORT supports downloading, and annunciating of SBL programs from a PC or any one of the above mentioned protocols. The HAND TERMINAL PORT supports communications to a handheld terminal for diagnostics or tuning or anyone of the above mentioned protocols. Selecting which protocol is to be used for each port is done through switch settings. Page 5

The above configuration would be used for communicating to both a programming computer and the handheld terminal The above configuration would be used to communicate to both a PLC or MMI and the Hand Held Terminal at the same time. The above configuration would be used to communicate to both a PLC or MMI and a programming computer. Note: Port functions are changed by switch settings only. No software changes are required for any of the above configurations. Programming The software implementation of the different protocols consists of 64 read Page 6

registers and 64 write registers that can be transferred between SAFphire and the PLC or MMI. These registers are accessed from the SBL program by using either a COMM READ REG block or a COMM WRITE REG block. Diagnostic information is available from a COMM STATUS block. For more information on using the individual blocks, please consult the Block Description Manual. All individual protocol parameters, i.e. baud rate, parity, etc. are not configurable. Please consult the appropriate App Note for individual protocol parameters. Both ports are accessed using the same COMM READ REG and COMM WRITE REG blocks. This allows a change in hardware configuration without changing the program. Page 7

SAFphire Ethernet Communications The CA418 Processor Card for SAFphire supports 10 MegaBaud ethernet communications between racks and for programming / annunciating. Physical connection to SAFphire can be made directly by using Unshielded Twisted Pair (UTP) cable with a RJ45 connector(10baset), or if a different physical medium is preferred, an AUI port is provided. Convertors can be purchased to convert AUI to any other physical meduim. The communication protocol used is IP. The IP address of each SAFphire is 192.168.250.Node. Node refers to the SAFphire Node Address which is set by SW1 and J7 (1-31). Note: For more information on switch settings, see CA418 Hardware Description. Programming / Annunciating When used for programming / annunciating purposes, ethernet provides fast throughput with low cost and readily available hardware. Ethernet cards are available in a variety of configurations to suit the computer being used (ISA, PCI, PCMCIA, Parallel Port). When used for downloading (code or programs) throughput of 15-20 Page 8

kbytes per seconds can be achieved. When used for annunciating, update times of 5 msec. are achievable. In order to communicate to SAFphire from SBL for Windows, the computer must have an ethernet card with the TCP/IP protocol installed. TCPIP Protocol Installation Using Windows 95 Control Panel, select Network. Check to see if TCP/IP is listed as one of the installed network components If it is not, select ADD Page 9

The Select Network Component Type Dialog Box will appear. Select Protocol, select ADD Change Manufacturers to Microsoft, select TCP/IP, select OK Page 10

Select the newly installed TCP/IP protocol and select properties. If only using the TCP/IP protocol for SAFphire communications, the only property that needs to be modified from default is the IP Address. Select the IP Address TAB, select Specify an IP address, change the IP Address to 192.168.250.X, where X is in the range of 33 to 254. This IP Address must be unique from other computers on the network. Set the Subnet Mask to 255.255.255.0. If TCP/IP is being used for more than SAFphire communications, please contact your network administrator for proper settings of the TCP/IP properties. Page 11

Configuring SBL To configure SBL for Windows for Ethernet Communications, select Options, Communications. Change the Protocol to UDP (the portion of IP that SBL uses). Select Setup, leave the Base IP Address at the default of 192.168.250.0, select OK, At this point if the communication module is successfully installed, the following dialog box will appear. Select OK, OK to return to SBL. Page 12

Rack to Rack Communications The built-in Ethernet port of the CA418 can be used to provide fast, deterministic Rack to Rack communications. SAFphires that are connected together on an ethernet network can broadcast Global Data to all other nodes on the network. Each node has 128 Global Data registers that are accessed by GLOBAL WRITE blocks. Each node can access the Global Data transmitted from any other nodes using GLOBAL READ blocks. Multiple SAFphires on the same ethernet network must all have unique node numbers as set by SW1 and J7. Note: For more information on switch settings, see CA418 Hardware Description. The frequency of the transmission of each nodes Global Data (if present) is determined by the total amount of global data present on the network. The following table indicates the time between successive transmissions of global data from any node. Because the transmissions are synchronous to the block program scans, the following times are minimums. Maximum times may be up to one program scan time longer Total Global Data (words) Time between transmissions (Msec.) 250 5 500 10 1000 20 4096 82 Each GLOBAL READ and GLOBAL WRITE block, reads or writes 8 words. The total Global Data can be calculated by simply summing the amount of Global Data transmitted by individual nodes on the network. The amount of Global Data transmitted by any individual node is equal to the largest offset in any of the Global Write blocks + 8. If no GLOBAL WRITE blocks are present, no Global Data is transmitted. For this reason, the first GLOBAL WRITE block should have an offset of 0, the second 8 etc. up to a maximum offset of 120 (128 registers minus 8) EXAMPLE: Assume a network of 8 SAFphires. Assume all offsets start at 0 and are sequential. Nodes 1-4 each have 4 GLOBAL WRITE blocks 8 Words X 4 Blocks X 4 Nodes = 128 Words Nodes 5 & 6 each have 6 GLOBAL WRITE blocks 8 Words X 6 Blocks X 2 Nodes = 96 Words Nodes 7 & 8 each have 2 GLOBAL WRITE blocks 8 Words X 2 Blocks X 2 Nodes = 32 Words Total = 256 Words Time = 5 Msec. Timeouts are handled without any user programming. Each GLOBAL Page 13

READ block has a STATUS output that will be ON if error free Global Data has been received from that node within the last 250 ms. Note: In order to minimize collisions, retries and possibly TIME OUTs due to an excessively loaded network, a dedicated ethernet network should be used for SAFphire. SBL Programming The following blocks will read 16 words from Nodes 1 and 2 Page 14

The following block will check the above blocks for a communication timeout. Note: only one status from each node must be checked. The following blocks will write the first 16 words of Global Data Page 15

SAFphire to Allen-Bradley PLC Communications Using DF1 The CA418 Processor Card for SAFphire and the OEM SAFphire allow for direct communications to Allen-Bradley PLC's using the DF1 protocol. DF1 is a full-duplex, point to point, RS232 communication link found on many Allen-Bradley PLC's. SAFphire will respond to messages initiated by a PLC. Using DF1, up to 64 words in both directions, can be transferred between a PLC and SAFphire. The following example transfers 64 words in both directions between a SLC504 and SAFphire. The PLC initiates all communications, with MSG blocks. Both the COMM READ REGISTERS and the COMM WRITE REGISTERS in SAFphire are mapped into N7:0. Doing reads or writes outside the range of N7:0 - N7:63 will give error responses. SBL Configuration DF1 Communications is available on either the HAND TERMINAL PORT or the DOWNLOAD PORT. Setting the appropriate switch (SW2 for the DOWNLOAD PORT, SW3 for the HAND TERMINAL PORT) to a setting of 1 will enable DF1 communications. Page 16

The following 4 blocks will load the first 32 COMM WRITE registers with data. This data is then read by the PLC as N7:0-N7:31. Four more blocks with offsets of 32, 40, 48, 56, would be required to load all 64 words with data Page 17

The following 4 blocks will read data from the first 32 COMM READ registers. This data must be sent from the PLC as a write to N7:0-N7:31. Four more blocks with offsets of 32, 40, 48, 56, would be required to read all 64 words. Page 18

PLC Configuration -SLC Family The PLC must have its RS232 port (also referred to as PROG TERM or CHANNEL 0) configured as follows The actual transfers of data occur using 2 MSG blocks. The ENABLE of the control block for the MSG instruction (bit 15 of the first word of the Control Block) is unlatched by the logical OR of the DONE (bit 13 of the first word of the Control Block) with the ERROR (bit 12 of the first word of the Control Block) The example rungs will continuously read 64 words from SAFphire at N7:0 and place them into N9:0. Also 64 words from N9:80 will be written to SAFphire at N7:0. Even though both the READS and WRITES use N7:0, the data will not be overwritten. Page 19

The following rungs will read 64 words from SAFphire at N7:0 to N9:0 The Setup Screen for the MSG Block is as follows. The Target Node is irrelevant as SAFphire will respond to all nodes. SAFphire only acknowledges messages with PLC5 addressing (Target Device must be set to PLC5) Page 20

The following rungs will write 64 words from N9:80 to SAFphire The Setup Screen for the MSG block is as follows The Target Node is irrelevant as SAFphire will respond to all nodes. SAFphire only acknowledges messages with PLC5 addressing (Target Device must be set to PLC5) Page 21

PLC Configuration -PLC 5 Family Newer PLC 5s have an additional file of type MG (message file). This should be used as the source of the Control Block. If your PLC 5 does not have files of type MG, please follow the SLC example. The PLC must have its RS232 port (also referred to as PROG TERM or CHANNEL 0) configured as follows The actual transfers of data occur using 2 MSG blocks. The ENABLE of the control block for the MSG instruction is unlatched by the logical OR of the DONE with the ERROR The example rungs will continuously read 64 words from SAFphire at N7:0 and place them into N9:0. Also 64 words from N9:80 will be written to SAFphire at N7:0. Even though both the READS and WRITES use N7:0, the data will not be overwritten. Page 22

The following rungs will read 64 words from SAFphire at N7:0 to N9:0 The Setup Screen for the MSG Block is as follows. The Target Node is irrelevant as SAFphire will respond to all nodes. SAFphire only acknowledges messages with PLC5 addressing (Command must be a PLC5 Typed Read) The following rungs will write 64 words from N9:80 to SAFphire Page 23

The Setup Screen for the MSG block is as follows The Target Node is irrelevant as SAFphire will respond to all nodes. SAFphire only acknowledges messages with PLC5 addressing (Command must be a PLC5 Typed Write) Page 24

Compatible Devices Compatible devices include SLC503, SLC 504, MicroLogix controllers, and the PLC5 family of A-B processors. NOTE: To ensure proper operation of the MSG instruction, upgrade the firmware of the PLC to the latest version available from A-B. Connections The RS232 port of A-B PLC's can be in the form of either a DB9 Male or a DB25 Female connector (a MiniDin style connector may also be available) Because no handshaking lines are used, only 3 terminals must be connecting. Connecting other terminals normally used for handshaking signals will not cause problems. DB9 Male (PLC) DB9 Male (SAFphire) 2 - Receive Data 3 - Transmit Data 3 - Transmit Data 2 - Receive Data 5 - Common 5 - Common DB25 Female (PLC) DB9 Male (SAFphire) 3 - Receive Data 3 - Transmit Data 2 - Transmit Data 2 - Receive Data 7 - Common 5 - Common NOTE: PLC5s can be configured for either RS422/485 or RS232 operation. (typically through DIP SWITCHES). Ensure RS232 is selected. Page 25

SAFphire to Modicon PLC Communications Using Modbus The CA418 Processor Card for SAFphire and the OEM SAFphire allow for direct communications to Modicon PLCs or other compatible devices using Modbus RTU. When connected to Modicon PLCs, SAFphire acts as a master on the network with the PLC being a slave device. Modbus RTU is a point to point, RS232 communication link found on many Modicon PLC's. SAFphire will initiate both READ HOLDING REGISTERS (0x03) messages and PRESET MULTIPLE HOLDING REGISTER (0x10) messages. Using MODBUS, up to 64 words total can be transferred between a PLC and SAFphire. The following example transfers 32 words in both directions between a Modicon PLC and SAFphire. SAFphire initiates all communications (master). SAFphire COMM READ REGISTERS and the COMM WRITE REGISTERS are mapped to holding registers 40001 to 40064 in the PLC. SBL Configuration Modbus Master RTU communications is available on either the HAND TERMINAL PORT or the DOWNLOAD PORT. Baud rates of either 9600 baud or 19200 baud are available. Setting the appropriate switch (SW2 for the DOWNLOAD PORT, SW3 for the HAND TERMINAL PORT) to a setting of 3 will enable Modbus Master communications @ 19200 baud. A setting of 4 will enable Modbus Master communications @ 9600 baud. Page 26

The following 4 blocks will write data to holding registers 40001 to 400032 in the connected PLC. NOTE: A block offset of 0 will write to holding register 40001-40008 Page 27

The following 4 blocks will read data from the holding registers 40033 to 40064 of the connected PLC. NOTE: A block offset of 32 will read from holding register 40033-40040 PLC Configuration Page 28

The PLC must have its RS232 port configured for Modbus RTU (not ascii). The PLC Address must be 1. The RS232 settings must be EVEN parity, 8 data bits, 1 stop bits. The baud rate setting must match the switch settings on SAFphire. Note: Modicon Micro PLC's do not support communications at 19200 baud Compatible Devices Compatible Modicon devices include the Micro, 984, and Quantum families of PLCs. Many other manufacturers also support Modbus communications. Connections The RS232 port of Modicon PLC's can be in the form of either a DB9 Female or a RJ45 Modular Connector. Modicon supplied cables are available for RJ45 to DB9 conversion. Because no handshaking lines are used, only 3 terminals must be connecting. Connecting other terminals normally used for handshaking signals will not cause problems. DB9 Female (PLC) DB9 Male (SAFphire) 2 - Receive Data 3 - Transmit Data 3 - Transmit Data 2 - Receive Data 5 - Common 5 - Common Page 29

SAFphire to Man-Machine-Interface Communications Using Modbus The CA418 Processor Card for SAFphire and the OEM SAFphire allow for direct communications to Man Machine Interfaces (MMIs) or other compatible devices using Modbus RTU. When connected to MMIs SAFphire acts as a slave device on the network with the MMI being a master device. SAFphire is also capable of being a Modbus Master device. See SAFphire to Modicon PLC App Note for more information. Modbus RTU is a point to point, RS232 communication link available with most MMIs. SAFphire will reply to READ HOLDING REGISTERS (0x03) messages, PRESET SINGLE HOLDING REGISTER (0x06), and PRESET MULTIPLE HOLDING REGISTER (0x10) messages. Using MODBUS, up to 64 words total can be transferred between a MMI and SAFphire. The following example transfers 32 words in both directions between a MMI and SAFphire. SAFphire only responds to MMI initiated messages (slave). SAFphire COMM READ REGISTERS and the COMM WRITE REGISTERS are presented to the MMI as to holding registers 40001 to 40064. SBL Configuration Modbus Slave RTU communications is available on either the HAND TERMINAL PORT or the DOWNLOAD PORT. Setting the appropriate switch (SW2 for the DOWNLOAD PORT, SW3 for the HAND TERMINAL PORT) to a setting of 2 will enable Modbus Slave communications. Page 30

The following 4 blocks will write data that can be read as holding registers 40001 to 400032 from the MMI. NOTE: A block offset of 0 will appear as holding register 40001-40008 Page 31

The following 4 blocks will read data that was written to holding registers 40033 to 40064 by the MMI. NOTE: A block offset of 32 will read data written to holding register 40033-40040 MMI Configuration The MMI must have its RS232 port configured for Modbus RTU (not ascii). The PLC Address of SAFphire is 1. The RS232 settings must be EVEN parity, 8 data bits, 1 stop bits, baud rate of 19200 Page 32

Compatible Devices Compatible devices include most MMI devices on the market Connections The connections for the RS232 ports of SAFphire are shown below. If the MMI requires the use of handshake signals (RTS, CTS, DTR, DSR), these must be connected internally to the MMI. Connecting other terminals normally used for handshaking signals will not cause problems. DB9 Male (SAFphire) 3 - Transmit Data 2 - Receive Data 5 - Common Page 33

1 P 1S P S 1 1 2 C 2 C B I T B 2 U S 2 3 3 3 A 3 A 1 C 4 4 C A 4 0C 3 A 4 0 3 _ 5 5 M U L TM I UP L 4 TE I P AL 4 E A 2 D 6 6 I N P U I T N / PO U U T T / PO UU TT P U T 7 7 C A R DC A R5 D B 5 B 3 D 8 8 _ - - 6 B 6 B 4 R - - I/P A 2I/P A 2 7 M 7 M 5 R 9 9 I/P B 1I/P B 1 1 1 0 1 0 8 M 8 M 2 6 R 1C 1 1 2 I/P A 1I/P A 1 3 9 C 9 C 4 1 3 1 3 5 1 4 I/P B 2I/P 1 0B 2 P 1S 0 P S 6 7 1 6 - - O / P 1 O / P 1 1 1 I 1 1 I 8 - - 1 2 C 1 2 C O / P 2 O / P 2 S A F 1 3 C 1 3 C B U S S A F S T A T U BS U S S T A T U S S A F S A F B U S B U S S T A T U SS T A T U S H A N CD A 4 0C 1 A 4 0 2 C A 4 0C 7 A 4 0C 7 A 4 1 0 T E R M D I ING A I TDL A I G L I T A L I N P U O T U TC P1 A U R T D 1 D R I V D E R I V M E O D B U S C A R I DN T E I RN FT A E CRP E FL / A U C S E / P O W E R E N C OE ND CE IRON DT E R F A C E 2 2 C A R DC A R DC A R D 3 3 8 0 4 4 1 S T A T U S 4 4 1 2 3 2 0 5 5 S T A 2 T U S 3 6 6 3 4 4 5 7 7 5 6 8 8 6 7 9 9 1 7 8 1 0 1 0 2 3 S T A T U S 8 9 1 1 1 1 4 5 1 0 1 2 1 2 6 C A 4 0 8 7 1 M U L T I S A F S A F 8 P R O C E S 1S 1 O R 1 3 1 3 B U S B U S C A R D S T A T U S S T A T U S 1 4 1 4 2 9 1 2 1 5 1 5 1 0 1 3 1 6 1 6 1 1 1 4 1 7 1 7 1 2 1 5 C A 4 0 9 1 8 1 8 S A F B U S 1 3 1 6 T E R M I N A T I O N / F A U L T R E L A Y 1 4 1 7 1 9 1 9 C A R D 1 5 1 8 2 0 2 0 1 6 1 9 2 1 2 1 2 0 2 2 2 2 2 3 2 3 I N P U OT SU T P U T S 2 4 2 4 FUS E SAFphire Application Notes SAF to ABB Drives Communications Using DDCS (point to point connection) DDCS is an ABB communications network implemented with fibre optics at 4 Mbaud. It is typically used for communications between SAFphire and an ABB Drive. Suitable SAFphire devices include an OEM SAFphire or a SAFphire with a CA417 or CA419. Suitable ABB drives include ACS600 and DCS500. 1 4 1 5 A C T I V E I N P U T S SAFphire 1 1 1 2 1 5 1 6 A C T I V E O U T P U T S T O C A 3 8 3 C A R D T O C A 3 8 3 C A R D M O D B U S P L U S 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 N O D E I D C O N F I G I O FU SE FU SE DDCS ACS600 OEM SAFphire ACS600 DDCS Page 34

Implementation DDCS is a master, slave protocol. The OEM SAFphire, CA417 or CA419 card is always the master and is assigned node 0. When using a CA417 card, the ACS600 or DCS500 drive should be configured as node 1 (node 1 is default setting). Both the OEM SAFphire and the CA419 support multiple nodes on the same channel in a ring configuration. This allows the node to be set in the range of 1 to 8. Information is exchanged in the form of datasets. A dataset consists of three 16 bit words (-32768 to 32767). Multiple datasets exist in the drive and are distinguished by number. Odd number datasets (i.e. 1,3and 5 ) are written from the master to the slave (from SAFphire to the drive), whereas even number datasets (i.e. 2,4 and 6 ) are read from the slave by the master (from the drive to SAFphire). Datasets are always used in pairs (i.e. 1&2, 3&4, 5&6). One pair of datasets provides 3 words of communications in both directions. NOTE CA417 ONLY (When using more than one pair of datasets they must be used in numeric order. Therefore using datasets 1&2 and 3&4 is valid but using datasets 1&2 and 5&6 is not valid and erroneous data will be passed back and forth. A maximum of 3 datasets (9 words) can be passed each way.) The number of datasets available from a given drive and their contents, is variable. With the DDCS protocol, one pair of datasets is updated every millisecond. If a slave device with one pair of datasets is being used, those datasets will be updated every millisecond. If a slave device with two pairs of datasets is being used, 1 pair of datasets will be updated every millisecond for a total update time of 2 milliseconds. Connections Hardware connection consists of two fiber optic cables. The first cable connects the transmitter of one device to the receiver of the second device. The second cable connects the receiver of the first device to the transmitter of the second device. Typically both fiber optic cables are bundled into one physical package (duplex cable). The two cable ends (transmitter and receiver) are colour coded. Insert the cable into the like coloured connector. Page 35

SBL Block Programming The following blocks would be used in the OEM SAFphire to read and write one pair of datasets to a ABB Drive setup as node 1. When acting as a master the node input of the DDCS blocks represents the node that you are requesting data from or writing data to. Page 36

The following blocks would be used in the SAFphire to read and write one pair of datasets to a ABB Drive setup as node 1. The card address input refers to the SAF Bus address being used by the CA417 or CA419 card. This input must match the setting of SW1 on the card. Valid addresses are 0-3 for a CA417 and 0-15 for a CA419. Page 37

SAFphire to DCS500B drive When using a DCS500 Drive, an additional communications board must be installed in the drive for DDCS communications. Either a COM1 or a COM5 board are suitable. A DCS500B Drive comes complete with the DDCS port included with the Drive. No additional communication board is required. A standard DCS500B drive has 4 Data Sets (1-4). Connect the onboard DDCS port of the DCS500B drive to the DDCS channel of SAFphire. The DDCS Node number of the drive is set in parameter 12.13. This must be 1 (default) when communicating to a CA417 card or equal to the NODE input of the DDCS blocks when using a CA419 card or OEM SAFphire. Data Sets 1 and 3 are used to send data from SAFphire to the drive. The parameters that contain the data from the Data Sets are shown below. Data Set Word Parameter DataSet 1 Word 1 10122 DataSet 1 Word 2 10123 DataSet 1 Word 3 10124 DataSet 3 Word 1 10125 DataSet 3 Word 2 10126 DataSet 3 Word 3 10127 In order to convert from a word to 16 individual bits, a function block must be enabled in the drive. NOTE: These instructions are written for a DDCS500B drive with firmware version 21.226. The firmware version of a particular drive can be found in parameter 112.18 CNT SW VERSION. The parameter numbers will be the same as far back as 21.105. For parameter numbers for future versions of firmware, or more information on function block programming, consult the APPLICATION BLOCKS for DCS500 Standard Drives Manual from ABB. 1) Using the Keypad, press FUNC followed by the double up arrow key then ENTER 2) Select (up/down arrows) ADD FUNCTION BLOCK, press ENTER 3) At the ENTER TASK NUMBER prompt press ENTER for TASK 1 (the fastest task time) 4) Using the double arrow keys select the first CONV IB (convert integer to bit) function block (442), press ENTER. 5) At the ENTER FB TAST POS prompt, press ENTER (selecting the next available function block position) 6) Select (up/down arrows) TERMINATE FB PROGR, press ENTER The Function block is now added, its inputs must now be connected before the outputs can be used. 7) Press PAR on the Keypad, The inputs to the function block are found at parameters 33.09 to 33.12. Tune CONV-IB[S] (33.09) to 125.02(on), Tune CONV-IB[L] (33.10) to 125.01(off). Tune CONV-IB[R] (33.11) to 125.01(off). Tune CONV-IB[IN] (33.12) to the parameter number of the word to be converted to bits (101.22 would be the first word of DataSet 1). Page 38

8) Tune parameter 25.04 FB_APPL_ENABLE to 1 to enable the added function blocks. 9) Tune parameter112.02 BACKUPSTOREMODE to SAVE MOT SET1 to save all changes 10) Cycle Power 11) The individual bits are now available in parameters 129.61 to 129.77 Data Sets 2 and 4 are used to send data from the drive to SAFphire. The parameters used to select which data is to be sent to SAFphire are shown below Data Set Word Parameter DataSet 2 Word 1 209 DataSet 2 Word 2 210 DataSet 2 Word 3 211 DataSet 4 Word 1 212 DataSet 4 Word 2 213 DataSet 4 Word 3 214 If individual bits are to be sent to SAFphire, They must first be converted to a word. 1) Using the Keypad, press FUNC followed by the double up arrow key then ENTER 2) Select (up/down arrows) ADD FUNCTION BLOCK, press ENTER 3) At the ENTER TASK NUMBER prompt press ENTER for TASK 1 (the fastest task time) 4) Using the double arrow keys select the first CONV BI (convert bit to integer) function block (445), press ENTER. 5) At the ENTER FB TAST POS prompt, press ENTER (selecting the next available function block position) 6) Select (up/down arrows) TERMINATE FB PROGR, press ENTER 7) The Function block is now added, its inputs must now be connected before the outputs can be used. 8) Press PAR on the Keypad, The inputs to the function block are found at parameters 33.17 to 33.35. Tune CONV-BI[S] (33.17) to 125.02(on), Tune CONV-BI[L] (33.18) to 125.01(off). Tune CONV-BI[R] (33.19) to 125.01(off). Tune CONV-BI[I1-i16] (33.20-35) to the parameters to be converted to a word. 9) Tune parameter 25.04 FB_APPL_ENABLE to 1 to enable the added function blocks. 10) Tune parameter112.02 BACKUPSTOREMODE to SAVE MOT SET1 to save all changes 11) Cycle Power 12) The word output is now available at parameter 129.95 Page 39

Parameters of interest Parameter 125.02 Always ON 125.01 Always OFF Function Page 40

SAFphire to DCS400 drive A DCS400 Drive comes complete with the DDCS port included. Connect the onboard DDCS port (V800) of the DCS400 drive to the DDCS channel of SAFphire. The DDCS Node number of the drive is set in parameter 2.10. This must be 1 (default) when communicating to a CA417 card or equal to the NODE input of the DDCS blocks when using a CA419 card or OEM SAFphire. Datasets From SAF to DCS400 Data Set Word Description Scaling Parameter To enable DDCS 8.01 = fieldbus DataSet 1 Word 1 Bit0=drive on Command 2.02= Bus Bit1=not coast Word 2.02= Bus Bit2=e-stop Can 2.02= Bus Bit3=drive run Be 2.02= Bus Bit4=not used Monitored Bit5=not used At Bit6=not used 2.05 Bit7=reset Bit8=jog 1 Bit9=jog 2 Bit10=not used Bit11=MCW BIT 11 9.05 Bit12= MCW BIT 12 9.05 Bit13= MCW BIT 13 9.05 Bit14= MCW BIT 14 9.05 2.02= Bus 2.02= Bus 2.02= Bus Bit15= MCW BIT 15 9.05 DataSet 1 Word 2 Bus Main Ref 20000=max speed 3.14, 3.15,5.01, DataSet 1 Word 3 Bus Aux Ref 4096=max cur 3.14, 3.15,5.01 DataSet 3 Word 1 Digital outputs 1-5 6.11-6.15 = 32 DataSet 3 Word 2 Analog Out 1 ±4096=±10V 6.05=9 DataSet 3 Word 3 Analog Out 2 ±4096=±10V 6.08=10 Page 41

Datasets From SAF to DCS400 Data Set Word Description Scaling Parameter DataSet 2 Word 1 Bit0=rdy for on Status Bit1=rdy for run Word Bit2=running Can Bit3=faulted Be Bit4=not coast Monitored Bit5=not e-stop At Bit6=not used 2.06 Bit7=alarm Bit8=at setpoint Bit9=remote Bit10=above limit Bit11=MSW BIT 11 6.22 Bit12=MSW BIT 12 6.23 Bit13=MSW BIT 13 6.24 Bit14=MSW BIT 14 6.25 Bit15=not used DataSet 2 Word 2 Actual 1 20000=maxspeed Set by 6.20 ±4096=±10V ana in DataSet 2 Word 3 Actual 2 4096 = max curr ±4096=±10V ana in Set by 6.21 DataSet 4 Word 1 Fld Cur Act 4096 = nom.cur DataSet 4 Word 2 Power Act 4096 = nom.power DataSet 4 Word 3 Torque Act 4096 = 100% The DCS400 detects a communication fault by monitoring for incoming messages. Even if the messages are erroneous or at the wrong baud rate the drive thinks everything is OK. Therefore if you only disconnect the transmitter from the drive the drive will not trip because it is still receiving initialization messages at different baud rates from the Safphire. You must monitor the communication in SAFphire and externally trip the drive on a communication fault. Page 42

SAFphire to ACS600 release 5 Drive Release 3 drives had the CH0 DDCS port included in the drive, release 5 drives require an NDCO card for DDCS communications to SAFphire. Connect CH0 from the NDCO card to SAFphire. Parameter Settings The ABB Manual for parameter descriptions for a standard drive is ACS600 Firmware Manual Standard Application Program 5.0 Most parameters are set according to the desired application. Some parameters that may be set differently or that have different options when using DDCS communications are shown below. No. Parameter Default Optional Setting 98.02 COMM MODULE NO FIELDBUS 70.01 CHANNEL 0 ADDR 1 NODE NUMBER* 90.01 D SET 3 VAL 1 0 DATA POINTER1* 90.02 D SET 3 VAL 2 0 DATA POINTER1* 90.03 D SET 3 VAL 3 0 DATA POINTER1* 92.02 D SET 2 VAL 2 102 DATA POINTER2* 92.03 D SET 2 VAL 3 105 DATA POINTER2* 92.04 D SET 4 VAL 1 305 DATA POINTER2* 92.05 D SET 4 VAL 2 308 DATA POINTER2* 92.06 D SET 4 VAL 3 306 DATA POINTER2* 10.01 EXT1 STRT/STP/DIR D1,D2 COMM MODULE 10.02 EXT2 STRT/STP/DIR NOT SEL COMM MODULE 10.03 DIRECTION FORWARD REQUEST 11.02 EXT1/EXT2 SELECT EXT 1 COMM REF 11.03 EXT REF 1 SELECT AI1 COMM REF 11.06 EXT REF 2 SELECT KEYPAD COMM REF 14.01 RELAY RO1 OUTPUT READY COMM MODULE 14.02 RELAY RO2 OUTPUT RUNNING COMM MODULE 14.03 RELAY RO3 OUTPUT FAULT (-1) COMM MODULE 30.18 COMM FAULT FUNC FAULT FAULT 30.19 COMM FLT TIME OUT 1.00 s 1.00 s 30.20 COMM FLT RO/AO ZERO ZERO *NODE NUMBER This is the desired DDCS node number of the drive. This must match be 1 if using a CA417 card. If using OEM SAFphire or a CA419 card, this number must match the NODE input to the block. *DATAPOINTER1 the function of the words in Data Set 3 are configurable by using pointers to the desired parameters to be written to. Setting a parameter to 102 will return parameter Group 1 offset 02. *DATAPOINTER2 the values returned in Data Sets 2 (except word 1) and 4 are configurable by using pointers to the desired parameters. The value returned in Data Set 2 Word 1 is always the STATUS WORD (parameter 3.02) The other values are determined by their appropriate parameter. Setting a parameter to 2301 will write the value into parameter Group 23 Offset 01. The datasets in a standard ACS600 release 5 drive are outlined below: Page 43

SAF toacs600 DataSet Word Function DataSet 1 Word 1 Bit 0 Enable (must see a OFF to ON transition after power up or after a fault reset) DataSet 1 Word 1 Bit 1 Reserved (turn ON) DataSet 1 Word 1 Bit 2 Reserved (turn ON) DataSet 1 Word 1 Bit 3 Run DataSet 1 Word 1 Bit 4 Zero Ramp Output (normal operation is ON) DataSet 1 Word 1 Bit 5 Ramp Hold (normal operation is ON) DataSet 1 Word 1 Bit 6 Zero Ramp Input (normal operation is ON) DataSet 1 Word 1 Bit 7 Fault Reset DataSet 1 Word 1 Bit 8 Reserved (turn off) DataSet 1 Word 1 Bit 9 Reserved (turn off) DataSet 1 Word 1 Bit 10 Reserved (turn ON) DataSet 1 Word 1 Bit 11 External Ctrl Loc (ON selects EXT CTRL 2, OFF selects EXT CTRL 1) DataSet 1 Word 1 Bit 12 Reserved (turn off) DataSet 1 Word 1 Bit 13 Reserved (turn off) DataSet 1 Word 1 Bit 14 Reserved (turn off) DataSet 1 Word 1 Bit 15 Reserved (turn off) DataSet 1 Word 2 Speed Reference (-20000 to 20000 scaled to parameter 11.3 in ACS600 DataSet 1 Word 3 Torque Reference (see below for scaling) Torque ref scaling If the torque control macro is selected, The torque reference is scaled such that 10000 to 10000 is scaled to parameter 11.8. If the standard macro is selected, The torque reference is scaled such that 20000 to 20000 is scaled to parameter 11.8. DataSet Word DataSet 3 Word 1 Bit 13 DataSet 3 Word 1 Bit 14 DataSet 3 Word 1 Bit 15 DataSet 3 Word 2 DataSet 3 Word 3 ACS to SAF Function Relay Output 1 (if parameter 14.01 set to COMM MODULE) Relay Output 2 (if parameter 14.02 set to COMM MODULE) Relay Output 3 (if parameter 14.03 set to COMM MODULE) Analog Output 1 (20000 = 20 ma) (if parameter 15.01 set to COMM MODULE) Analog Output 2 (20000 = 20 ma) (if parameter 15.01 set to COMM MODULE) DataSet Word Function DataSet 2 Word 1 Bit 0 Ready to switch ON DataSet 2 Word 1 Bit 1 Ready to Operate DataSet 2 Word 1 Bit 2 Operation Enabled DataSet 2 Word 1 Bit 3 Fault (ON = faulted) DataSet 2 Word 1 Bit 4 OFF 2 DataSet 2 Word 1 Bit 5 OFF 3 DataSet 2 Word 1 Bit 6 Switch On Inhibited DataSet 2 Word 1 Bit 7 Alarm (ON = Alarm) DataSet 2 Word 1 Bit 8 At Setpoint DataSet 2 Word 1 Bit 9 Remote (ON = Remote Mode, OFF = Local) DataSet 2 Word 1 Bit 10 Above Limit DataSet 2 Word 1 Bit 11 External Control Location(ON = EXT2, OFF = EXT1) DataSet 2 Word 1 Bit 12 Run enable signal received DataSet 2 Word 1 Bit 13 Reserved DataSet 2 Word 1 Bit 14 Reserved Page 44

Slave (node 1) Slave (node 2) SAFphire Application Notes DataSet 2 Word 1 Bit 15 DDCS error DataSet 2 Word 2 Parameter Selected by 92.02 DataSet 2 Word 3 Parameter Selected by 92.03 See ACS600 Firmware Manual Standard Application Program 5.0 Appendix C for more information on Control and Status words. These datasets are for a standard drive. Custom firmware is available that may have different datasets. Consult the vendor for information on custom firmware. Multi Node DDCS Communications Note: Users without basic DDCS knowledge should first consult the SAFphire to ABB Drives Communications App Note. Multi Node DDCS communications can be used to communicate from one DDCS master to multiple DDCS slaves connected in a ring configuration. Suitable DDCS Master devices OEM SAFphire. Suitable DDCS Slave devices include ACS600 drives, DCS500 drives, OEM SAFphires or a SAFphire with a CA417 card (node 1 only). The master and slave nodes will be connected in a ring configuration. The transmitter of the master is connected to the receiver of the first slave. The transmitter of the first slave is connected to the receiver of the next slave. This continues until the transmitter of the last slave is connected to the receiver of the master. The update time for the DDCS protocol is one pair of datasets per node per 1 msec. A network of one slave device and using only one pair of datasets will have an update time of 1 msec. A network with 2 slave devices, each with 2 datasets, will have an update time of 4 msec The node number of an ACS600 drive is controlled from parameter 60.5 Master(node OEM SAFphire 0) Network Slave(node 3) Master OEM (node SAFphire 0) & ABB Drives Slave (node 3) Slave(Node 1) Slave(node2) Page 45

SBL Block Programming The following 4 blocks would be used in the master node OEM SAFphire to read and write one pair of datasets to two slave devices setup as node 1 and node 2. When acting as a master the node input of the DDCS blocks represents the node that you are requesting data from or writing data to. Page 46

The following 2 blocks would be used in the slave OEM SAFphire (node 1) to reply to the master OEM SAFphire s request for data. When acting as a slave the node input on the DDCS blocks represents the slave node number that you would like the OEM SAFphire to be defined as. The following 2 blocks would be used in the slave OEM SAFphire (node 2) to reply to the master OEM SAFphire s request for data. When acting as a slave the node input on the DDCS blocks represents the slave node number that you would like the OEM SAFphire to be defined as. Page 47

SAFphire to SAFphire Communications Using DDCS (point to point) Note: Users without basic DDCS knowledge should first consult the SAFphire to ABB Drives Communications App Note. DDCS can be used for communication between two DDCS capable SAFphire devices. DDCS capable devices include OEM SAFphire or a SAFphire with a CA417 card. DDCS is a master, slave protocol. SAFphire with a CA417 card can be a master or a slave with a node number of 1. OEM SAFphires can be a master or a slave devices with a node number of 1-8. Information is passed between nodes in the form of datasets. Each dataset consists of three 16 bit words (-32768 to 32767), and is assigned a number. Odd number datasets (i.e. 1,3and 5) are written by the master node to the slave node. Even number datasets (i.e. 2,4 and 6) are read by the master node from the slave node. For this reason the datasets are always used in pairs (i.e. 1&2, 3&4, 5&6). When using more than one pair of datasets they must be used in numeric order. Using datasets 1&2 and 3&4 is valid but using datasets 1&2 and 5&6 is not valid and erroneous data will be passed back and forth. A maximum of 3 datasets (9 words) can be passed each way. The update time for the DDCS protocol is equal to one pair of datasets per msec. A network consisting of one slave device with one pair of datasets would be updated once every millisecond. If you are using two pairs of datasets each pair of datasets will be updated once every two milliseconds. Page 48

Connections Hardware connection consists of two fiber optic cables. The first cable connects the transmitter of one device to the receiver of the second device. The second cable connects the receiver of the first device to the transmitter of the second device. Typically both fiber optic cables are bundled into one physical package (duplex cable). The two cable ends (transmitter and receiver) are colour coded. Insert the cable into the like coloured connector. OEM SAFphire and CA417 connections are shown below. Communications between CA417 and OEM SAFphire is also valid. ADDRESS 1 ADDRESS 1 Page 49

SBL Block Programming OEM SAFphire Master The following 4 blocks would be used in the master node OEM SAFphire to read and write two pairs of datasets to a DDCS slave setup as node 1. When acting as a master the node input of the DDCS blocks represents the node that you are requesting data from or writing data to. Page 50

OEM SAFphire Slave The following 4 blocks would be used in the slave OEM SAFphire to reply to the DDCS master messages for datasets 1 and 2. When acting as a slave the node input on the DDCS blocks represents the slave node number that you would like the OEM SAFphire to be defined as. Page 51

SAFphire and CA417 as Master The following 4 blocks would be used in the master CA417 to read and write two pairs of datasets to DDCS Slave configured as node 1. There is no node input because a master CA417 is always node 0 and can only communicate to node 1. The card address input refers to the card address being used by the CA417 card. This input must match the setting of SW1 on the CA417 card (range is 0-3). Page 52

SAFphire and CA417 as Slave The following 4 blocks would be used in the slave CA417 to reply to the DDCS master messages for datasets 1 and 2. There is no node input because a slave CA417 is always node 1. The card address input refers to the card address being used by the CA417 card. This input must match the setting of SW1 on the CA417 card (range is 0-3). Page 53

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