ACS850 Application guide Fieldbus control with FPBA-01 PROFIBUS DP adapter module and ABB AC500
ACS850 Drive Manuals DRIVE HARDWARE MANUAL* ACS850-04 Drive Modules (1.
Fieldbus control with FPBA-01 PROFIBUS DP adapter module and ABB AC500 PLC Application guide 3AUA0000089372 Rev A EN EFFECTIVE: 2010-10-30 © 2010 ABB Oy. All Rights Reserved.
Table of contents Table of contents Introduction to the manual Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
References and scaling in torque control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Actual values and scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Actual values in speed control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Actual values in torque control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to create and configure buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 How to create indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Running and testing the program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 How to download the program to the controller and run the program . . . . . . . . . . . . . . . . .
Table of contents
Introduction to the manual What this chapter contains This chapter describes the target audience, purpose and contents of this manual. Applicability The manual is compatible with ACS850-04 drive modules of frame sizes from A to G. Safety instructions Follow the safety instructions given in ACS850-04 Drive Modules (1.1 to 45 kW) Hardware Manual – 3AUA0000045496 (English). The main instructions are repeated below.
Target audience This manual is intended for people who plan the drive application control, commission, use, and service the drive with fieldbus communication. Read the ACS850 firmware and hardware manuals before working on the drive. You are expected to know the fundamentals of electricity, wiring and electrical components as well as drive control methods, fieldbus communication concepts and function block programming.
• ACS850-04 Drive Modules (200 to 500 kW) Hardware Manual (3AUA0000026234 [English]) • ACS850 Standard Control Program Firmware Manual (3AUA0000045497 [English]) • PROFIBUS DP Adapter Module FPBA-01 User’s Manual (3AFE68573271 [English]) • User Manual for PLC Programming with CoDeSys 2.3 by 3S – Smart Software Solutions GmbH • ABB AC500 scalable programmable logic controller manuals.
Introduction to the manual
Fieldbus control description What this chapter contains The chapter describes how the drive can be controlled by external devices over a communication network. The chapter describes parameters related to the communication and the drive control. System overview The drive can be connected to a fieldbus controller via a fieldbus adapter module. The adapter module is connected to drive Slot 3.
– Ethernet/IPTM (FENA-01 adapter) – EtherCAT (FECA-01 adapter) Setting up communication through a FPBA-01 fieldbus adapter module Before configuring the drive for fieldbus control, the adapter module must be mechanically and electrically installed according to the instructions given in the FPBA-01 user’s manual. The communication between the drive and the fieldbus adapter module is activated by setting parameter 50.01 FBA ENABLE to (1) ENABLE. The adapter-specific parameters must also be set.
Setting for fieldbus control Applicationspecific setting 51.02 NODE NUMBER 0...126 2 Each device on the Profibus network must have an unique node number. This parameter is used to define a node number for the drive it is connected to. 51.03 BAUD RATE 12000 12000 6000 This paremeter indicates the detected communication speed in kbit/s. 3000 12000 = 12 Mbit/s 1500 6000 = 6 Mbit/s 500 3000 = 3 Mbit/s 187 1500 = 1.5 Mbit/s 93 500 kbit/s 45 187 = 187.5 kbit/s 19 93 = 93.
Parameter Setting for fieldbus control Applicationspecific setting Function/Information 51.31 D2FBA COMM STA – Displays the status of the fieldbus adapter module communication. 51.32 FBA COMM SW VER – Displays the common program revision of the adapter module. 51.33 FBA APPL SW VER – Displays the application program revision of the adapter module. Note: In the User’s Manual of the fieldbus adapter module, the parameter group number is 1 or A for parameters 51.01…51.26.
Parameter Setting for fieldbus control Applicationspecific setting Function/Information 53.01 FBA DATA OUT 1 1 Control word 53.02 FBA DATA OUT 2 2 Reference 1 (16-bit) 53.03 FBA DATA OUT 3 3 Reference 2 (16-bit) Note: In the User’s Manual of the fieldbus adapter module, the parameter group number is 3 or C for parameters 52.01…52.12 and 2 or B for parameters 53.01…53.12. 51.27 FBA PAR REFRESH (1) REFRESH Validates any changed adapter module configuration parameter settings.
The fieldbus control interface The cyclic communication between a fieldbus system and the drive consists of 16/ 32-bit input and output data words. The drive supports at the maximum the use of 12 data words (16-bit) in each direction. Data transmitted from the drive to the fieldbus controller (PLC) is defined by parameters 52.01…52.12 (FBA DATA IN) and data transmitted from the (PLC) fieldbus controller to the drive is defined by parameters 53.01…53.12 (FBA DATA OUT).
The Control Word and the Status Word The Control Word (CW) is the principal means of controlling the drive from a fieldbus system. The Control Word is sent by the fieldbus controller to the drive. The drive switches between its states according to the bit-coded instructions of the Control Word. The Status Word (SW) is a word containing status information, sent by the drive to the fieldbus controller.
PPO Types The PPO (parameter process data object) consists of parameter identification (PKW) and process data (PZD). The PKW is used for reading and writing parameters. The PZD is used for transmitting Control Word, Status Word, Reference values, Actual values and other process data.
FBA communication profile The FBA communication profile is a state machine model which describes the general states and state transitions of the drive. The State diagram on page 20 presents the most important states (including the FBA profile state names). The FBA Control Word (parameter 2.24) commands the transitions between these states and the FBA Status Word (parameter 2.26) indicates the status of the drive.
State diagram The following presents the state diagram for the FBA communication profile. FBA Communication Profile from any state from any state (FBA CW Bits 7 = 1) Fault (FBA SW Bit 16 = 1) FAULT RUN DISABLE (FBA SW Bit 1 = 0) (FBA CW Bit 7 = 0) (FBA CW Bit 8 = 1) Par. 10.19 = 1 FBA CW = Fieldbus Control Word FBA SW = Fieldbus Status Word n = Speed I = Input Current RFG = Ramp Function Generator f = Frequency E (FBA CW Bit 16 = 1) Par. 10.
Communication profiles Overview This chapter describes the communication profiles used in the communication between the PROFIBUS network, the FPBA-01 module, and the drive. Communication profiles Communication profiles are ways of transmitting control commands (Control word, Status word, references and actual values) between the master station (PLC) and the slave station (Drive). With the FPBA-01 module, the PROFIBUS network may employ either the PROFIdrive profile or the ABB Drives profile.
FPBA-01 Drive FPBA-01 profile selection: PROFIdrive Data conversion * ABB Drives Select Data conversion * Select PROFIBUS CW REF1 REF2 SW ACT1 ACT2 Transparent16 Optional reference/ actual value scaling 16/32bit Group A, Par. 5 PROFIdrive positioning Data conversion ** Group A, Par. 5 Transparent32 PROFIBUS PZDx • • 16/32• bit • PZD10 Note: The diagram is applicable only when PPO messaging is used. If Standard Telegrams (ST) are used, the communication profile is selected automatically.
The PROFIdrive communication profile The Control Word and the Status Word The Control Word (PROFIBUS Parameter 967) is the principal means for controlling the drive from a fieldbus system. It is sent by the fieldbus master station (PLC) to the drive through the adapter module. The drive switches between its states according to the bit-coded instructions on the Control Word, and returns status information to the master in the Status Word (PROFIBUS Parameter 968).
Setting up communication through a FPBA-01 fieldbus adapter module on page 14 for the drive parametrization. Actual values in speed control mode The scaling of 16-bit actual speed values (ACT or NIST_A) in hexadecimal (0…4000h) corresponds to 0…100% maximum reference. The speed scaling is defined by the drive parameter 19.01. Example: to set the PROFIdrive communication profile scaling ratio 1:1. The drive parameter 19.01 is set to 16384 (4000h).
The Control Word for the PROFIdrive communication profile The upper case boldface text refers to the states shown on page 30. Bit Name Value Proceed to STATE/Description Speed control mode 0 1 2 ON 1 Proceed to READY TO OPERATE. OFF1 0 Emergency OFF, stop by the selected deceleration ramp. Proceed to OFF1 ACTIVE; proceed further to READY TO SWITCH ON unless other interlocks (OFF2, OFF3) are active. OFF2 1 Continue operation (OFF2 inactive). 0 Emergency OFF, coast to stop.
Bit Name Value Proceed to STATE/Description Speed control mode 11 1 Vendor-specific bit as defined by PROFIdrive parameter 933. 0 12 Vendor-specific bit as defined by PROFIdrive parameter 934. 13 Vendor-specific bit as defined by PROFIdrive parameter 935. 14 Vendor-specific bit as defined by PROFIdrive parameter 936. 15 Vendor-specific bit as defined by PROFIdrive parameter 937.
Bit Name Value STATE/Description Speed control mode 9 10 11 REMOTE 1 Drive control location: REMOTE. 0 Drive control location: LOCAL. 1 Actual frequency or speed value equals or is greater than supervision limit. 0 Actual frequency or speed value is within supervision limit. 1 Vendor-specific bit as defined by PROFIdrive parameter 939. 0 12 Vendor-specific bit as defined by PROFIdrive parameter 940. 13 Vendor-specific bit as defined by PROFIdrive parameter 941.
The general PROFIBUS state machine for all operating modes SWITCH-ON INHIBIT MAINS OFF PROFIBUS State Machine (SW Bit6=1) OFF1 (CW Bit0=0) Power ON NOT READY TO SWITCH ON A B C D CW = Control Word SW = Status Word n = Speed I = Input Current RFG = Ramp Function Generator f = Frequency (SW Bit0=0) (CW=xxxx x1xx xxxx x110) (CW Bit3=0) READY TO SWITCH ON OPERATION INHIBIT (SW Bit0=1) (SW Bit2=0) operation inhibited from any state Fault ON (CW=xxxx xxxx xxxx x111) READY TO OPERATE from any
The ABB Drives communication profile The Control Word and the Status Word The Control Word is the principal means for controlling the drive from a fieldbus system. It is sent by the fieldbus master station to the drive through the adapter module. The drive switches between its states according to the bit-coded instructions on the Control Word, and returns status information to the master in the Status Word.
References are scaled as shown below. Note: The scaling values of REF1 MAX and REF2 MAX for speed and torque are set by drive parameters 19.01 and 24.05, respectively. Fieldbus Drive REF2: 10000 REF1: 20000 0 REF2: -10000 REF1: -20000 REFx MAX REFx MIN -(REFx MIN) -(REFx MAX) Actual values and scaling Actual values are 16-bit words that contain information on the operation of the drive.
Note: The scaling values of REF1 MAX and REF2 MAX for speed and torque are set by drive parameters 19.01 and 24.05 respectively. Fieldbus Drive REF2: 10000 REF1: 20000 0 REF2: -10000 REF1: -20000 REFx MAX REFx MIN -(REFx MIN) -(REFx MAX) The Control Word for the ABB Drives communication profile. The upper case boldface text refers to the states shown in State machine, ABB Drives communication profile. Bit Name Value STATE/Description 0 OFF1_ CONTROL 1 Proceed to READY TO OPERATE.
Bit Name Value STATE/Description 5 RAMP_HOLD 1 Enable ramp function. Proceed to RAMP FUNCTION GENERATOR: ACCELERATOR ENABLED. 6 7 RAMP_IN_ ZERO RESET 0 Halt ramping (Ramp Function Generator output held). 1 Normal operation. Proceed to OPERATING. Note: This bit is effective only if the fieldbus interface is set as the source for this signal by drive parameters. 0 Force Ramp Function Generator input to zero. 0=>1 Fault reset if an active fault exists. Proceed to SWITCH-ON INHIBITED.
Bit Name Value STATE/Description 5 OFF_3_STA 1 OFF3 inactive. 0 OFF3 ACTIVE. SWC_ON_ INHIB 1 SWITCH-ON INHIBITED 0 – ALARM 1 Warning/Alarm. 0 No warning/alarm. 1 OPERATION. Actual value equals reference = is within tolerance limits, i.e. in speed control, speed error is 10% max. of nominal motor speed. 0 Actual value differs from reference = is outside tolerance limits. 1 Drive control location: REMOTE (EXT1 or EXT2). 0 Drive control location: LOCAL.
State machine, ABB Drives communication profile SWITCH-ON INHIBITED MAINS OFF Power ON (SW Bit6=1) (CW Bit0=0) NOT READY TO SWITCH ON A B C D (SW Bit0=0) (CW=xxxx x1xx xxxx x110) (CW Bit3=0) READY TO SWITCH ON OPERATION INHIBITED (SW Bit0=1) (SW Bit2=0) operation inhibited (CW=xxxx x1xx xxxx x111) READY TO OPERATE from any state OFF1 (CW Bit0=0) OFF1 ACTIVE (CW=xxxx x1xx xxxx 1111 and SW Bit12=1) (SW Bit1=0) n(f)=0 / I=0 B C D (SW Bit1=1) ABB Drives Communication Profile CW = Control W
Installation and parameter setup for communication profiles Overview This chapter presents the steps to take during the start-up of the FPBA-01 PROFIBUS DP Adapter Module and the ACS850 drive. This chapter presents examples for different applications such as speed and torque control, sending reference over fieldbus and scaling.
PROFIdrive communication profile (Speed Control Mode) PPO Type 4 The start/stop commands and reference are according to the PROFIdrive profile Speed Control Mode. This example employs PPO Type 4 cyclical message. Set parameters as given in the Application-specific setting column in the table below. A reference value of ±16384 (4000h) corresponds to parameter 19.01 SPEED SCALING in forward and reverse directions.
Fieldbus parameters The Application-specific setting column is a setup for speed control, using PROFIdrive profile and PPO type 4. Parameter Application-specific setting Function/Information COMMUNICATION INITIALISATION AND SUPERVISION 50.01 FBA ENABLE (1) ENABLE Initialises communication between drive and fieldbus adapter module. 50.02 COMM LOSS FUNC (1) FAULT Selects how the drive reacts in a fieldbus communication break. 50.03 COMM LOSS T OUT 0.
Application-specific setting Parameter Function/Information TRANSMITTED DATA SELECTION FROM DRIVE TO PLC 52.01 FBA DATA IN1 ... 52.12 FBA DATA IN12 Defines the data transmitted from drive to fieldbus controller and further to the PLC. Parameters are set according to the virtual address area of the drive. Note: If the length of the selected data is 32 bits, two parameters are reserved for the transmission. 52.01 FBA DATA IN1 4 Status word (16-bit). Mapping: PZD1 52.
Drive control parameters for the PROFIdrive profile in DriveStudio Installation and parameter setup for communication profiles
Installation and parameter setup for communication profiles
The Control Word is used for sending commands from a master (PLC) to a slave unit (Drive). Control Word and Status Word can be monitored from the PLC. The start sequence for this example is given in the table below.
ABB DRIVES communication profile (Speed/Torque Control Mode) with PPO Type 5 The start/stop commands and reference are according to the ABB DRIVES profile Speed Control Mode. When Reference 1 (REF1) is used, a reference value of ±20000 (4E20h) corresponds to 0 ... 100% of maximum reference. The speed scaling is defined by the drive parameter 19.01 in the forward and reverse directions. When Reference 2 (REF2) is used, a reference value of ±10000 (2710h) corresponds to 0 ... 100% of maximum reference.
Fieldbus parameters The Application-specific setting column is a setup for speed/torque control, using ABB drives profile and PPO type 5. Parameter Application-specific setting Function/Information COMMUNICATION INITIALISATION AND SUPERVISION 50.01 FBA ENABLE (1) ENABLE Initialises communication between drive and fieldbus adapter module. 50.02 COMM LOSS FUNC (1) FAULT Selects how the drive reacts in a fieldbus communication break. 50.03 COMM LOSS T OUT 0.
Application-specific setting Parameter Function/Information 51.06 T16 SCALE 0 Reference multiplier/actual value divisor for the FPBA01. The parameter is only effective when Transparent 16 profile is selected and the drive is using FBA communication profile. 51.27 FBA PAR REFRESH 1 Validates any changed adapter module configuration parameter settings. Note: In the User’s Manual of the fieldbus adapter module, the parameter group number is 1 or A for parameters 51.01…51.26.
Drive control parameters for the ABB Drives profile in DriveStudio Installation and parameter setup for communication profiles
Installation and parameter setup for communication profiles
The Control Word is used for sending commands from a master (PLC) to a slave unit (Drive). The start sequence for speed control in this example is given in the table below.
The start sequence for torque control in this example is given in the table below.
Transparent16 communication profile (Speed Control Mode) PPO Type 5 The start/stop commands and reference are according to the Transparent16 control mode. This example employs cyclical message type; PPO Type 5. Set parameters as given in the Application-specific setting column in the table below. A reference value of 0 to 65536 corresponds to parameter 51.06 T16 SCALE.
Fieldbus parameters The Application-specific setting column is a setup for speed control, using T16 profile and PPO type 5. Parameter Application-specific setting Function/Information COMMUNICATION INITIALISATION AND SUPERVISION 50.01 FBA ENABLE (1) ENABLE Initialises communication between drive and fieldbus adapter module. 50.02 COMM LOSS FUNC (1) FAULT Selects how the drive reacts in a fieldbus communication break. 50.03 COMM LOSS T OUT 0.
Application-specific setting Parameter Function/Information TRANSMITTED DATA SELECTION FROM DRIVE TO PLC 52.01 FBA DATA IN1 ... 52.12 FBA DATA IN12 Defines the data transmitted from drive to fieldbus controller and further to the PLC. Parameters are set according to the virtual address area of the drive. Note: If the length of the selected data is 32 bits, two parameters are reserved for the transmission. 52.01 FBA DATA IN1 4 Status word (16-bit). Mapping: PZD1 52.
Drive control parameters for the Transparent16 profile in DriveStudio Installation and parameter setup for communication profiles
Installation and parameter setup for communication profiles
The Control Word is used for sending commands from a master (PLC) to a slave unit (Drive). The start sequence for this example is given in the table below. Step Instruction Control Word (Hex) Operation Status Word 1 Power up 0x0000 At setpoint. Zero speed. 0x2100 2 Reset fault (bit 8) Remote command (bit 11) 0x0900 Drive ready. 0x2101 3 Start (bit 1) Remote command (bit 11) 0x0802 Drive ready. 0x2101 4 Start (bit 1) Run enable (bit 7) Remote command (bit 11) 0x0882 Enabled.
Starting up fieldbus communication and programming the ABB PLC What this chapter contains This chapter presents the steps to take during the start-up of the drive fieldbus control with ABB AC500 PLC and PROFIBUS DP adapter module. The chapter introduces the communication setup, the PLC program, visualizations and how to run and test the program.
Equipment and programs Equipment used in the examples: • ACS850 demosuitcase (order code 3AUA0000050654) containing one ACS850-04--03A0-5 drive with FPBA-01 PROFIBUS DP Adapter Modules • AC500 demosuitcase TA510-CASE: AC500 PLC *) equipped with a CPU of type PM571 and a communications module, CM572-DP, for communication over PROFIBUS DP fieldbus. Programs used in the examples: • ACS850 Standard Control Program version UMFI 2020 • ABB DriveStudio PC tool • AC500 Control Builder PS501 *).
Start-up flowchart The steps of the start-up procedure are presented below. Perform the steps from first to last. No. Task Description / See instruction ELECTRICAL INSTALLATION 1 Connect the PC RJ-45 cable to drive terminal X7. In this section, you wire the equipment used in this programming example. ACS850-04 Drive Modules (1.1 to 45 kW) Hardware Manual (3AUA0000045496 [English]) Page 61 2 Connect the PLC fieldbus master (CM572-DP) to the fieldbus adapter module (FPBA-01) of the drive.
No. 2 Task Set up the communication. Description / See instruction In this section, communication between the PLC and the drive is configured. Setting up the communication, page 69 • Create a new project, page 69 • Configure communication with the SYCON.net fieldbus configurator, page 75 3 PLC main program introduction. In this section, PLC main program is introduced.
Connections PC: - DriveStudio - AC500 Control Builder PS501 ACS850-04 COM 6 5 FPBA-01 1 ACS850-04 Democase with FPBA-01 module installed to the slot 3. Module is connected to the CM572-DP Profibus master.
Installing the DriveStudio PC tool Insert the DriveStudio installation CD into the CD drive of your the PC. Follow the instructions given by the installation program. For more information, see DriveStudio online Help folder DriveStudio: Installing and uninstalling. Installing the AC500 Control Builder PS501 software 1. Insert the AC500 Control Builder PS501 installation CD into the CD drive of your PC. Click the Read me first button and read the instructions. 2. Click the Installation PS501 button. 3.
Installing additional GSD files You can find the GSD files for the FPBA-01 module on the manufacturer’s website. 1. Go to www.abb.com and select Product Guide / Drives / Drive Options / Fieldbus options. 2. From the Please select category list, select “...FPBA-01 - PROFIBUS (4)” .
3. Under Software, download FPBA-01 Profibus DP Adapter GSD Files. Note: Under Manual, you can also download FPBA-01 Profibus DP Adapter Module User's Manual 4.
Step Setting the drive control program parameters This section lists the ACS850 Standard Control Program parameter settings that you need to set for successful communication with the FPBA-01 fieldbus adapter module. This setup is for the ABB Drives profile. Set all other necessary parameters to meet the application needs.
Setting the drive control program parameters Step 1. Open the DriveStudio. Set the parameters listed below. This setup is for the ABB Drives profile.
Step Setting the drive control program parameters Starting up fieldbus communication and programming the ABB PLC
Starting up fieldbus communication and programming the ABB PLC
Tool/Step Setting up the communication This section contains detailed instuctions on how to configure Profibus DP network using the CodeSys program and SYCON.net configuring tool. The instructions illustrate how the network is configured with the ready-made project ABB_drives_PB_demo.pro. The CodeSys project ABB_drives_PB_demo.pro is stored in the ABB library, “vault ID” part 2. CoDeSys You can use ABB_drives_PB_demo.pro without changes or modify the selections by using the instructions below.
Tool/Step Setting up the communication 4. In the New POU dialog box, select as shown below. 5. The programming view opens. Open the Resources field by clicking its tab.
Tool/Step Setting up the communication 6. In the Resources folder, double-click PLC Configuration. 7. In the PLC Configuration dialog box, click the plus sign to open the AC500 folder.
Tool/Step Setting up the communication 8. If you are using an I/O bus, add the relevant I/O bus to the system configuration. Right-click the I/O Bus[FIX] folder. Select Append Subelement and select one of the I/O bus options (example: AX522 - 8 analog Input and 8 analog Output…). 9. In the Interfaces [FIX] folder, right-click the FBP-none[SLOT] file and select Replace element and FBP - Slave.
Tool/Step Setting up the communication 10. Right-click the Couplers[FIX] folder. Select Append Subelement and CM572 External-Profibus DP Master… 11. In the Couplers[FIX] folder, right-click the Internal - none[SLOT] file and select Replace element and PM5x1-ETH - Internal-Ethernet.
Tool/Step Setting up the communication 12. Right-click the Couplers[FIX] folder. Select Append Subelement and External none… 13. From the File menu, select Save as and name the project. Click Save.
CoDeSys Tool/Step Setting up the communication Configure communication with the SYCON.net fieldbus configurator 1 Click the Resources tab to show the Resources folders. 2. Under Tools, double-click SYCON.net .
SYCON.net Tool/Step Setting up the communication 3. The SYCON.net tool opens: 4. From the Network menu, select the Device Catalog… command. Click the Reload button. PROFIBUS options appear in the ABB Oy folder. Click OK.
Tool/Step 5. Setting up the communication Drag and drop CM572-DPM on the green line. In the netConnect-Driver Parameter dialog box, select 1 for the Board no: box. This is because the CM572DP communications module is installed next to the CPU on the left-hand side in the installation example of this manual.
Tool/Step 6. Setting up the communication Drag and drop the FPBA-01 DP-V1 on the purple line.
Tool/Step Setting up the communication 7. In the netDevice field, right-click the CM572-DPM icon. Select Configuration. In the Navigation area field, click 3S Gateway Driver. Click the Gateway Configuration button. 8. In the Communication Parameters dialog box, set the communication parameters according to the communication settings of your PC. See Appendix A - How to find out the serial communication parameter values of your PC?.
Tool/Step Setting up the communication 9. In the Navigation area, click Device Assingnment. Activate the device by ticking it. 10. In the Navigation area, click Configuration / Bus Parameters. In the Bus Parameters dialog box, set the Baud Rate. If there is warning sign, click the Adjust button and set the other timing parameters.
Tool/Step 11. Setting up the communication In the Navigation area, click Configuration / Station Table. Set the station address for the FPBA-01. Click the Apply button and then OK. Note: The station address here must be the same as the value of Parameter 51.02 FBA PAR2 in the drive control program. Set parameter Parameter 51.02 FBA PAR2 with DriveStudio.
Tool/Step 12. Setting up the communication Right-click the ABB Drives FPBA-01 icon connected to the purple line in the netDevice field. In the Navigation area field, click Modules in the Configuration folder. In the Available modules: box, select PPO-05. Click the Insert button and then Apply.
Tool/Step 13. Setting up the communication In the Configuration folder, click Parameters. Set the values of parameters Fail Safe mode and Control-zero mode as shown below. Click Apply and then OK.
Tool/Step 14. Setting up the communication In the netConnect field, click PPO-5, 4PKW + 10 PZD . A list of inputs and outputs appears.
Tool/Step 15. Setting up the communication Name the signals in the netConnect field. See the designation of the signals in the image below. Note: You can name all signals here and they will be automatically declared in the Control Builder. 16. Check that the PLC is in the Stop state (Stop in the display). Note: The downloading is not possible if the PLC is in the Run state.
Tool/Step Setting up the communication 17. Download the communication configuration to the PLC: first, right-click the CM572DPM icon and, then click Download. 18. When the downloading is completed, right-click the CM572-DPM icon and then click Disconnect. 19. Save the project with the Save command under the File menu. 20. Close the SYCON.net tool.
CoDeSys Tool/Step 21. Setting up the communication Declared variables are now in the Resources sheet, under Global variables -> Slot 1 -> Slot1_Slave2.
Starting up fieldbus communication and programming the ABB PLC
Tool/Step Introduction to the PLC main program This section introduces the ABB_Drives_PB_demo.pro main program and the global and local variable lists. If you want to modify the ready-made project ABB_Drives_PB_demo.pro, see How to add function blocks on page 92. For detailed function block descriptions, refer to • CoDeSys Online Help (Press F1 in the CoDeSys software) • User Manual for PLC Programming with CoDeSys 2.
Tool/Step 2. Introduction to the PLC main program The function blocks of the main program on rows 1 to 4 are shown below. The function blocks on rows 1 to 3 show the inputs and outputs of Control Word and Status Word. A function block on row 4 declare action presented in section Introduction to the actions on page 97.
Tool/Step Introduction to the PLC main program Local variables Local variables are located above the main program function blocks. The Declare Variable assistant writes variables to the local or global variable list based on your selection. All local variables used in project ABB_Drives_PB_demo.pro are shown below. Global variables Global variables are located under the Resources tab. The Declare Variable assistant writes variables to the local or global variable list based on your selection.
Tool/Step Introduction to the PLC main program How to add function blocks This section instructs you how to add function blocks to the project, if needed. However, it is not necessary for you to modify the project, as it is already functional. 1. To create a new programmable area, right-click on the blank area and select Network (after) or Network (before) from the menu.
Tool/Step Introduction to the PLC main program 2. To add function blocks, click the Box button in the tool bar. 3. Replace the default text AND with text “any function block”. The CoDeSys program recognizes the function block and the block appearance changes automatically. Note: Function block descriptions and other relevant data are available in the online help, click F1 to start.
Tool/Step Introduction to the PLC main program 4. Name the function block as you wish and press Enter. 5. The Declare Variable assistant appears. In the Class dialog box, select the desired variable class. The content of the Type box is configured automatically according to the function block type. Click OK. Note: If you want to call the Declare Variable assistant again, click the desired variable and press Shift+F2. Note: When defining inputs, you can use the Input assistant.
Tool/Step 6. Introduction to the PLC main program Configure inputs and outputs. While naming the inputs, the Declare Variable assistant appears each time you enter an unknown variable.
Starting up fieldbus communication and programming the ABB PLC
Tool/Step Introduction to the actions This section presents the scaling action of project ABB_Drives_PB_demo.pro. This action is used for a speed reference and an actual value scaling according to the ABB Drives profile. At the end of this section, there are also brief instructions How to create actions, in case you want to modify the ready-made project ABB_Drives_PB_demo.pro.
Tool/Step Introduction to the actions speed_scaling When a boolean "activate_scaling" is TRUE, action ‘speed_scaling’ scales the speed reference and the actual value according to the ABB Drives profile.
CoDeSys Tool/Step Introduction to the actions How to create actions 1. In the POUs field, right-click PLC_PRG(PRG) and select Add Action. 2. Name the action and select the programming language (options below). Click OK.
Tool/Step Introduction to the actions 3. An empty programmable space appears. Program the action. 4. Remember to declare all the actions in the main program PLC_PRG.
Tool/Step Introduction to the visualizations This section presents visualizations. Visualizations are the user interfaces for the PLC program: buttons, switches and indicators for controlling, measuring and viewing the movement. If you want to modify the ready-made project ABB_Drives_PB_demo.
Tool/Step Introduction to the visualizations How to create an empty visualization field Click the Visualization tab. Right-click the Visualizations folder. From the menu that opens, select Add Object…. Name the new visualization and click OK. A platform for the new visualization is created. How to create and configure buttons 1. Create buttons for the switches needed. In the upper tool bar, click the OK button and, with the cursor, drag a rectangle in the visualization field.
Tool/Step Introduction to the visualizations 2. Configure the button as follows. Right-click the button. From the menu opening, select Configure. 3. In the Category: dialog box, select Text. In the Text Content: dialog box, write a name for the button.
Tool/Step 4. Introduction to the visualizations In the Category: dialog box, select Input. Under Input, tick Toggle variable or Tap variable and write the name of the input to the dialog box. Click OK. Note: When defining inputs, you can use the Input assistant. Click on Toggle variable field and press F2. With the button created you can switch the value of a global variable (in this case, activate_scaling) between TRUE and FALSE.
Tool/Step Introduction to the visualizations How to create indicators 1. A meter indicator is created as follows. In the upper tool bar, click the Meter button and, with the cursor, drag a bar in the visualization field. Configure meter dialog box opens. Click the Varible/Scale button.
Tool/Step 2. Introduction to the visualizations Set the scale. Write the name of the indicated variable (in this case Variable: speed_act). Click OK and OK. The indicator has been created. Note: When defining inputs, you can use the Input assistant. Click on Toggle variable field and press F2.
Tool/Step Running and testing the program CoDeSys In this section, you download the program to the PLC. Thereafter, you can run the program and test it. How to download the program to the controller and run the program 1. Check that the AC500 PLC and ACS850 drive are switched on and connections are made properly. See page 61.
Tool/Step 2. Running and testing the program From the Online menu, select Communication Parameters…. Check that the communication parameters correspond to the serial/ethernet port of your PC (see Appendix A - How to find out the serial communication parameter values of your PC?).
Tool/Step 3. Running and testing the program From the Online menu, click Login. The program asks you to download the program to the controller. Click Yes. If you get a communication error message, then the connection between the PC and the PLC is not properly established. Check the cables and connections. From the Online menu, select Communication Parameters… and remove irrelevant communication parameters. Configure the communication with the SYCON.net again and download the configuration.
Tool/Step Running and testing the program ABB Drives profile; Run at reference speed 1. With DriveStudio, configure drive parameters according to the ABB Drives profile. For parametrization examples for the different communication profiles, see Installation and parameter setup for communication profiles, page 37.
Tool/Step 2. Running and testing the program From the Online menu, select Run. The program starts running and you can test its features.
Tool/Step 3. Running and testing the program Reset any active faults, set Control word bits 7 and 10 to TRUE(1). To set a bit value to TRUE, toggle the gray button next to the bit indicator. The green box next to the button indicates boolean TRUE (1). Control word: 0x480. Status word: 0x380.
Tool/Step 4. Running and testing the program Set the drive ready to turn on. Set following Control word bits to TRUE(1): 10,6,5,4,3,2,1. Control word: 0x47e. Status word: 0x1331.
Tool/Step 5. Running and testing the program Start modulation: set the following Control word bits to TRUE(1): 10,6,5,4,3,2,1,0. Control word: 0x47f. Status word: 0x1337.
Tool/Step 6. Running and testing the program The project contains a scaling function for the ABB Drives profile. The speed scaling function enables entering a reference speed in rpm. To activate speed scaling, toggle button: Activate speed scaling. Insert desired reference speed to Ref 1 (rpm) field and press enter. The drive ramps up to the reference speed. You can monitor the actual speed in the Act 1 (rpm) field and also from speedometer below the field.
Tool/Step Running and testing the program ABB Drives profile; Stopping 1. ABB Drives profile state machine defines actions to take, when disabling certain bits of the Control word. When the drive is running at reference speed, you can test different stop modes by disabling each Control word bit at a time: Bit 0: Stop along currently active decelarion ramp, ACS850 parameter 22.03 or 22.05. Proceed to OFF1 ACTIVE; proceed to READY SWITCH-ON, unless other interlocks (OFF2, OFF3) are active.
Tool/Step Running and testing the program 2. Bit 1: Emergency OFF, coast to stop. Proceed OFF2 active; proceed to SWITCHON INHIBITED. CW: 0x47d, SW: 0x12e0. 3. Bit 2: Emergency stop, according emergency stop ramp, defined by ACS850 parameter 22.12. Proceed to OFF3 ACTIVE; proceed to SWITCH-ON INHIBITED. CW: 0x47b, SW: 0x12d0.
Tool/Step Running and testing the program 4. Bit 3: Inhibit operation, coast to stop. Proceed to OPERATION INHIBITED. CW: 0x477, SW: 0x233. 5. Bit 4: Force ramp function generator output to zero. Current and DC- voltage limits in force. CW: 0x46f, SW: 0x1237.
Tool/Step Running and testing the program 6. Bit 5: Halt ramping. Ramp generator input on hold. CW:45f, SW: 1337. 7. Bit 6: Force ramp function generator input to zero. Ramp function generator input is zero. CW:43f, SW: 1337.
Tool/Step Running and testing the program ABB Drives profile: Run at reference torque 1. Reset any active faults. Set Control word bits 7,10 and 11 to TRUE(1). The green box next to the button indicates boolean TRUE (1). Control word: 0xc80. Status word: 0xb80.
Tool/Step 2. Running and testing the program Set the drive ready to operate. Set following Control word bits to TRUE(1): 11,10,3,2,1. Control word: 0xc0e. Status word: 0x1b31.
Tool/Step 3. Running and testing the program Start operating. Set following Control word bits to TRUE(1): 11,10,3,2,1,0. Control word: 0x0c0f. Status word: 0x1a37.
Tool/Step 4. Running and testing the program Run at reference torque. The scaling of torque is according to the ABB Drives profile. Reference 10000 corresponds to 100.00 % torque. Insert desired reference torque to Ref 2 (PZD 3) field and press enter. The drive ramps up to the reference torque. If the speed limit (par 20.01) is met, the motor runs at TORQ REF SP LIM (par 3.12) to prevent motor rush. You can monitor actual torque in the Act 1 (PZD 3) field.
Tool/Step Running and testing the program ABB Drives profile; Parameter handling (PKW 1-4 Read/Write) Reading a parameter 1. In cyclic PROFIBUS DP communication, parameter data is transfered in PPO message types PPO 1, 2 and 5. The Parameter Identification part consists of eight bytes. For information on parameter handling, PROFIBUS DP Adapter Module FPBA-01 User’s Manual (3AFE68573271 [English]). To read/write a parameter, a request is sent from the master (PLC) to the slave (drive).
Tool/Step 2. Running and testing the program Below, the drive parameter 19.01 SPEED SCALING is read.
Tool/Step Running and testing the program ABB Drives profile; Parameter handling (PKW 1-4 Read/Write) Writing a parameter 3. Below, parameter 20.01 MAXIMUM SPEED value 1330 is written.
Tool/Step Running and testing the program Parameter handling; mapping parameters to the cyclic process data (PZD) communication channel 1. Parameters can be mapped from the drive side by using groups 52 and 53. Open DriveStudio. Use parameter groups 52 and 53 to map parameters. To read a parameter, map it to the group 52 and to write a parameter map it to the group 53 respectively. For example: to read output frequency, parameter value 52.04 is set to value 0103 (corresponding to parameter 01.
Tool/Step 2. Running and testing the program In the image below: The value of parameter 1.03 OUTPUT FREQUENCY is read from the drive parameters 52.04 and 52.05. This mapping example employs process data channel Read PZD 4 and 5. Frequency is 1363 which corresponds to 13.63 Hz. Parameter 11.06 DC HOLD is written to the mapped drive parameter 53.04. This mapping example employs process data channel Write PZD 4. In this case parameter 11.06 value is changed to 1 (Enabled).
Tool/Step Running and testing the program How to perform online monitoring 1. While running the program, you can use CoDeSys for online monitoring. The image below presents inputs and outputs of the drive.
Tool/Step 2. Running and testing the program The image below presents the main program. While running, the blue color indicates boolean value TRUE. To force a variable value change, double-click the variable and enter new value. Press F7 to execute the forced change.
Tool/Step 3. Running and testing the program Monitoring speed_scaling action. To force a variable value change, double-click the variable and enter new value. Press F7 to execute the forced change.
Starting up fieldbus communication and programming the ABB PLC
ACS850 Crane Control Program supplement What this chapter contains This chapter presents parameter configuration and utilization demonstrations for ACS850 (+N697) Crane control program over Profibus DP fieldbus. For the crane control you can use a ready-made CodeSys project ABB_Drives_ACS850_crane_control.pro. The project and the parameter file is in the ABB library, “vault ID” part 2. The project ABB_Drives_ACS850_crane_control.
Tool/Step Crane control program supplement Electrical installation Electrical installation is similar to page 61. Follow the installation instructions in the chapter Start-up flowchart on page 59. In the following image a FPBA-01 Profibus communication module is installed to ACS850-04 drive option slot 3. A Profibus cable is connected to the FPBA-01 module and the module is connected with the cable to the CM572 Profibus DP master.
Tool/Step Crane control program supplement Parametrization 1. Set the ACS850 Crane Control Program parameter settings given in this section for successful communication with the FPBA-01 fieldbus adapter module. The following setup is intended for the ABB Drives profile. Set all other necessary parameters to meet your application needs. For more information on the parameters refer to the manual: ACS850 Crane Control Program supplement (3AUA0000081708 [English].
Tool/Step 2. Crane control program supplement Open the DriveStudio. Set the parameters listed below. This setup is according to the ABB Drives profile.
Tool/Step Crane control program supplement Appendix A - How to find out the serial communication parameter values of your PC?
Tool/Step Crane control program supplement Crane control program fieldbus commands Following commands are send to a slave (drive) by a fieldbus master (PLC). Start the drive The start sequence for the speed control is given in the table below. Reset faults, if any. Set the drive to Ready to operate, then to Start operating. Give speed reference. The motor accelerates until it is running at the reference speed. To change direction give negative reference; follow steps below. Stop the drive 1.
Tool/Step 3. Crane control program supplement OFF3: Emergency stop. Stop along currently active emergency stop ramp, defined by ACS850 parameter 22.12. Proceed to OFF3 ACTIVE; proceed to SWITCH-ON INHIBITED. Brake ON. Function: Drive ramps to a 0-speed according to the emergency stop ramp and activates brake, field excitation is disabled. To start again execute steps 3 and 4. 4. Force ramp function generator to zero.
Tool/Step Crane control program supplement Fault simulation; reset and start again 1. Safe Torque Off is opened to simulate fault while running. The table below describes the steps to take to reset and start the drive again. Function: When the Safe Torque Off is trigged: Drive trips, torque is disabled, brake is enabled and motor stops. To start again: check that STO circuit is closed. Execute step 3 to reset the fault. Execute steps 4 and 5 in order to run the drive again.
Tool/Step Crane control program supplement Utilization with CodeSys and AC500 PLC How to download the program to the controller and run the program 1. Check that the AC500 PLC and ACS850 drive are switched on and the connections are made properly, refer to the page 61. 2. From the Online menu, select Communication Parameters….
Tool/Step 3. Crane control program supplement From the Online menu, click Login. The program asks you to download the program to the controller. Click Yes. If you get a communication error message, then the connection between the PC and the PLC is not properly established. Check the cables and connections. From the Online menu, select Communication Parameters… and remove irrelevant communication parameters. Configure the communication with the SYCON.net again and download the configuration.
Tool/Step 4. Crane control program supplement From the Online menu, select Run. The program starts running and you can test its features.
Tool/Step Crane control program supplement ABB Drives profile; Run at reference speed 1. First reset any active faults, set Control word bits 7 and 10 to TRUE(1). To set a bit value to TRUE toggle gray button next to the bit indicator. The green box next to the button indicates boolean TRUE (1). Control word: 0x480. Status word: 0x380.
Tool/Step 2. Crane control program supplement Set the drive ready to run. Set the following Control word bits to TRUE(1): 10,6,5,4,3,2,1. Control word: 0x47e. Status word: 0x1331.
Tool/Step 3. Crane control program supplement Start modulating: set the following Control word bits to TRUE(1): 10,6,5,4,3,2,1,0. Control word: 0x47f. Status word: 0x1337.
Tool/Step 4. Crane control program supplement This project contains a scaling function for the ABB Drives profile. The speed scaling function enables to enter a reference speed in rpm. To activate speed scaling, toggle button: Activate speed scaling. Insert desired reference speed to Ref 1 (rpm) field and press enter. The drive ramps up to the reference speed. You can monitor actual speed in the Act 1 (rpm) field and also from speedometer below the field.
Tool/Step Crane control program supplement ABB Drives profile; Stopping 1. The ABB Drives profile state machine defines the actions to take, when disabling certain bits of the Control word. When drive is running at reference speed, you can test different stop modes by disabling each Control word bit at a time: Bit 0: Stop along currently active deceleration ramp, ACS850 parameter 22.03 or 22.05. Proceed to OFF1 ACTIVE; proceed to READY SWITCH-ON, unless other interlocks (OFF2, OFF3) are active.
Tool/Step 2. Crane control program supplement Bit 2: Emergency stop, according emergency stop ramp, defined by ACS850 parameter 22.12. Proceed to OFF3 ACTIVE; proceed to SWITCH-ON INHIBITED. CW: 0x47b, SW: 0x12d0.
Tool/Step 3. Crane control program supplement Bit 6: Force ramp function generator input to zero. Ramp function generator input is forced to zero. Field excitation stays enabled. CW:43f, SW: 1337.
Tool/Step Crane control program supplement ABB Drives profile; Run at reference torque 1. First reset any active faults, set Control word bits 7,10 and 11 to TRUE(1). The green box next to the button indicates boolean TRUE (1). Control word: 0xc80. Status word: 0xb80.
Tool/Step 2. Crane control program supplement Set the drive ready to operate. Set following Control word bits to TRUE(1): 11,10,3,2,1. Control word: 0xc0e. Status word: 0x1b31.
Tool/Step 3. Crane control program supplement Start operating. Set following Control word bits to TRUE(1): 11,10,3,2,1,0. Control word: 0x0c0f. Status word: 0x1a37.
Tool/Step 4. Crane control program supplement Run at reference torque. The scaling of torque is according to the ABB Drives profile. Reference 10000 corresponds to 100.00 % torque. Insert the desired reference torque to Ref 2 (PZD 3) field and press enter. The drive ramps up to the reference torque. If Speed limit (par 20.01) is met, the motor runs at TORQ REF SP LIM (par 3.12) to prevent motor rush. You can monitor actual torque from the Act 1 (PZD 3) field.
Appendix A - How to find out the serial communication parameter values of your PC? What this chapter contains This chapter instructs how to find out the serial communication parameter values of your PC. Tool/Step Go to Windows Control Panel and click the System icon. Microsoft Windows 1.
Tool/Step How to find out the serial communication parameter values of your PC? 2. Click the Hardware tab and then the Device Manager button. 3. In the Ports (COM & LPT) folder, click Communications Port, which is connected to AC500, in this case port (COM1).
Tool/Step 4. How to find out the serial communication parameter values of your PC? The communication port settings are shown.
Appendix A - How to find out the serial communication parameter values of your PC?
Further information Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/drives and selecting Sales, Support and Service network. Product training For information on ABB product training, navigate to www.abb.com/drives and select Training courses.
3AUA0000089372 / EN EFFECTIVE: 2010-10-30 ABB Oy Drives P.O. Box 184 FI-00381 HELSINKI FINLAND Telephone +358 10 22 11 Fax +358 10 22 22681 www.abb.com/drives ABB Inc. Automation Technologies Drives & Motors 16250 West Glendale Drive New Berlin, WI 53151 USA Telephone 262 785-3200 1-800-HELP-365 Fax 262 780-5135 www.abb.com/drives ABB Beijing Drive Systems Co. Ltd. No. 1, Block D, A-10 Jiuxianqiao Beilu Chaoyang District Beijing, P.R. China, 100015 Telephone +86 10 5821 7788 Fax +86 10 5821 7618 www.abb.
