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09/2002
Instruction Bulletin Raleigh, NC, USA
ALTIVAR® 58 TRX
Adjustable Speed Drive
Controllers
FIPIO® Protocol Communication Card
User’s Guide
VW3A58301U
Retain for future use.
DANGER
HAZARDOUS VOLTAGE
• Read and understand this bulletin in its entirety before installing
or operating ALTIVAR 58 TRX drive controllers. Installation,
adjustment, repair, and maintenance of the drive controllers must
be performed by qualified personnel.
• The user is responsible for conforming to all applicable code
requirements with respect to grounding all equipment.
• Many parts in this drive controller, including printed wiring boards,
operate at line voltage. DO NOT TOUCH. Use only electrically
insulated tools.
• DO NOT short across DC bus capacitors or touch unshielded
components or terminal strip screw connections with voltage
present.
• Before servicing the drive controller:
— Disconnect all power including external control power that may
be present before servicing the drive controller.
— Place a “DO NOT TURN ON” label on the drive controller
disconnect.
— Lock the disconnect in open position.
— WAIT TEN MINUTES for the DC bus capacitors to discharge.
Then follow the DC bus voltage measurement procedure on
page 7 to verify that the DC voltage is less than 45 V. The drive
controller LEDs are not accurate indicators of the absence of
DC bus voltage.
• Install and close all covers before applying power or starting and
stopping the drive controller.
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FIPIO Protocol Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REVISION LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ADDITIONAL DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
RECEIVING, PRELIMINARY INSPECTION, AND STORAGE . . . . . . . . . . . . . . . . . . 7
BUS VOLTAGE MEASUREMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Card Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Setting a FIPIO Address for the ATV58 TRX Drive Controller . . . . . . . . . . . . . . . 11
CONNECTING TO THE FIPIO BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cable Routing Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FIPIO Card Display LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CONFIGURING COMMUNICATION FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FIPIO Bus Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SOFTWARE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FIPIO CONFIGURATION USING PL7 PRO SOFTWARE . . . . . . . . . . . . . . . . . . . . . 17
About FIPIO Standard Profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Data Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Implicit Data for ATV58 TRX Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . 20
Explicit Data for ATV58 TRX Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . 23
Effect and Use of the WRITE_PARAM function . . . . . . . . . . . . . . . . . . . . 24
Effect and Use of the READ_PARAM function . . . . . . . . . . . . . . . . . . . . . 24
Effect and Use of the SAVE_PARAM function . . . . . . . . . . . . . . . . . . . . . 24
Effect and Use of the RESTORE_PARAM function . . . . . . . . . . . . . . . . . 25
Diagnostic Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
PROGRAMMING THE PLC USING PL7 PRO SOFTWARE FOR THE ATV58 TRX
DRIVE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Configuring the ATV58 TRX Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CONTROL SCHEME OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Forced Local . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Hand/Off/Auto (HOA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Communication Fault Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Protection of Adjustment and Configuration Access . . . . . . . . . . . . . . . . . . . . 35
Access Protection by Forced Local . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INTRODUCTION
WARNING
LOSS OF CONTROL
• The control scheme designer must consider the potential failure
modes of control paths.
• Certain critical control functions provide a means to achieve a
safe state during and after a path failure. 1
• Separate or redundant control paths must be provided for critical
control functions.
• System control paths may include communication links.
Consideration must be given to the implications of unanticipated
transmission delays or failures of the link. 2
Failure to follow this instruction can result in death, serious
injury, or equipment damage.
1 Examples of critical control functions are emergency stop and overtravel stop.
2
For additional information, refer to NEMA ICS 1.1 (latest edition), “Safety Guidelines for
the Application, Installation, and Maintenance of Solid State Control” and to NEMA
ICS7.1 (latest edition), “Safety Standards for Construction and Guide for Selection,
Installation and Operation of Adjustable-Speed Drive Systems.”
REVISION LEVEL
ADDITIONAL DOCUMENTATION
DANGER
HAZARDOUS VOLTAGE
• Read and understand the bus voltage measurement procedure
before performing the procedure. Measurement of bus capacitor
voltage must be performed by qualified personnel.
• Many parts in this drive controller, including printed wiring boards,
operate at line voltage. DO NOT TOUCH. Use only electrically
insulated tools.
• Do not short across DC bus capacitors or touch unshielded
components or terminal strip screw connections with voltage
present.
The DC bus voltage level is determined by monitoring the (+) and (–)
measurement points. Their location varies by drive controller model
number as listed in Table 1 and shown in Figure 1. The drive
controller model number is listed on the nameplate.
The J18 connector is in the upper left hand corner of the main
control board behind the flexible shield. Use a thin probe to access
the connector pin.
J18-7
–
+ } ATV58•U29M2–D12M2
ATV58•U18N4–D23N4
J18
Flexible
Shield L1 L2 L3 PA PB U V W
+
– } ATV58•U09M2–U18M2
L1 L2 + – U V W
+
Main Control
Board – } ATV58•D16M2–D46M2
ATV58•D28N4–D79N4
L1 L2 L3 + – PA PB U V W
Power
Terminal
Block
INSTALLATION
Card Installation
2
RUN
ERR
5 COM
I/O 1
POWER z 3 0
FAULT
6
4 3
Self-Adhesive Label
0 0 0 0
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
NOTE: Do not ever give two devices on the FIPIO bus the same
address. Continued simultaneous flashing of the standard LEDs
indicates that the device cannot connect to the FIPIO bus because its
address is already occupied by another device.
Figure 4: Connecting the ATV58 TRX Drive Controller to the FIPIO Bus
TSXLES••
TSXFPACC7
ATV58 TRX controller ATV58 TRX controller
TSXFPCA•••
TSXFPACC12 TSXFPACC12
(with ATV58E•••••, (with ATV58E•••••,
use TSXFPACC2) use TSXFPACC2)
TSXFPACC7
Green: RUN
Yellow: COM
Red: I/O
0
1 8
Address switches
Table 2 shows what the LED states indicate for each of the four
LEDs.
RUN LED ERR LED COM LED I/O LED What is indicated
On Off Rapid flash 1 Off Normal operation
Auto-test at
Flashes Flashes Flashes Flashes initialization or
communication fault
On On Serious fault
On Off On Minor internal fault
Off Off Off Off Not operating.
1
The COM LED flashes rapidly when there are communication exchanges on the bus and
is off when there are no exchanges.
NOTE: For more information on faults and fault codes, refer to the
instruction bulletin supplied with your drive controller.
SOFTWARE SETUP
Figure 6 shows how to verify the protocol (FIPIO in this case) and the
communication address as read from the card switches by using the
drive controller's keypad display.
ENT ENT
8.Communication
SL Protocol
-Pro FIPIO
-Pro
ESC ESC
ENT
Comm.Addr.
AdrC Comm.Addr.
1
(Example for address 1)
ESC
structure FSD C8P. The profile defines the FIPIO bus connection
point parameters where:
• C: indicates compact
• 8: is the number of cyclical I/O objects managed by the PLC
• P: indicates additional parameters, namely 16 configuration words
and 32 adjustment words.
In PL7 Pro software, for ATV58 TRX drive controllers, this profile is
predefined and transparent to the user because the software allows
for selection of the drive controller by its part number.
Data Exchange
Data exchanges between the PLC and the drive controller over a
FIPIO network fall into two categories, implicit exchanges and explicit
exchanges. Implicit exchanges are done automatically by the PLC
and no additional programming is required to obtain and transfer
these implied data objects. Implicit data is also called cyclic or
periodic data because it is refreshed every PLC scan cycle. Explicit
data exchanges, on the other hand, require additional programming
in the PLC and the use of specific communication request codes to
obtain data, or to read and write specific variables.
Upon each logical reconnection of the ATV58 TRX drive controller to
the FIPIO bus, the PLC loads the drive controller with the following:
• 16 configuration objects (%KW\p.2.c\0.0.0 to %KW\p.2.c\0.0.15),
containing the data for 32 ATV58 configuration parameters
• 32 adjustment parameters (%MW\p.2.c\0.0.4 to
%MW\p.2.c\0.0.35)
This initialization occurs under the following conditions:
• Every time the drive controller power is cycled when connected to
the FIPIO bus
• On reconnection of the drive controller to the FIPIO bus after it
has been physically disconnected
• On reconnection of the PLC (bus master) to the FIPIO bus
A summary of the data exchanged using the FSD C8P profile, along
with the object types used in PL7 programming, is given in Table 3.
Tables 4 and 5 describe the ATV58 TRX drive controller words that
are exchanged with the PLC on a periodic basis, or every scan cycle
of the PLC. The PLC performs a cyclical refresh of all %IW registers
at the beginning of the drive controller program task. The %QW
registers are also refreshed at the end of the PLC’s program task.
The output of the ATV58 TRX drive controller responds to the values
sent by the PLC each time an application program execution cycle is
completed. However, if the values sent by the PLC are not received
for a period of at least 256 ms, the drive controller parameters are set
to their default values and the controller stops the motor on the
deceleration ramp.
Returning to normal communication automatically places the drive
controller under the control of the PLC once again, and if the network
run command is issued, the drive controller will start the motor.
The %IW, %QW, and %KW words are explained in the ATV58
Register Access Guide for Communication Networks,
VVDED397058US.
There are also 32 drive controller configuration words that can be
managed by implicit exchange in the PLC via 16 programming object
references. The 16 word references are used in groups of bits or
whole words to indicate the value of the parameters. These values
are coded in hexadecimal format. Table 6 describes the drive
controller parameters used. See page 29 to set up the configuration
using PL7 Pro software.
Drive Controller
PL7 Object
Controller Parameter Description
Reference
Register Codes
%KW\p.2.c\0.0.0
W11 ORT • Standard/High torque selection
%KW\p.2.c\0.0.1 W3 CFG • Macro Configuration—Handling, General
Use, Variable Torque
W101 LI2
%KW\p.2.c\0.0.2 Assignment of logic inputs LI2 and LI3
W102 LI3
Assignment of:
Drive Controller
PL7 Object
Controller Parameter Description
Reference
Register Codes
%KW\p.2.c\0.0.10 W55 UNS 1 Motor nameplate voltage
%KW\p.2.c\0.0.11 W53 FRS 1 Motor nameplate frequency
%KW\p.2.c\0.0.12 W54 NCR 1 Motor nameplate current
1
%KW\p.2.c\0.0.13 W56 NSP Motor nameplate speed
%KW\p.2.c\0.0.14 W57 COS 1 Motor nameplate power factor
%KW\p.2.c\0.0.15 W52 TFR 1 Maximum output frequency
%KW\p.2.c\0.0.16 W287 PIC 1 Inverts the PI feedback signal
1
These parameter values are determined based on the drive controller model number selected in PL7 Pro
software during configuration.
Drive Drive
Object Reference Controller Object Reference Controller
Code Code
%MW\p.2.c\0.0.4 HSP %MW\p.2.c\0.0.20 TLS
%MW\p.2.c\0.0.5 LSP %MW\p.2.c\0.0.21 RPG
%MW\p.2.c\0.0.6 ACC %MW\p.2.c\0.0.22 RIG
%MW\p.2.c\0.0.7 DEC %MW\p.2.c\0.0.23 FBS
%MW\p.2.c\0.0.8 ITH %MW\p.2.c\0.0.24 JPF
%MW\p.2.c\0.0.9 reserved %MW\p.2.c\0.0.25 TL2
%MW\p.2.c\0.0.10 reserved %MW\p.2.c\0.0.26 FTD
%MW\p.2.c\0.0.11 AC2 %MW\p.2.c\0.0.27 CTD
%MW\p.2.c\0.0.12 DE2 %MW\p.2.c\0.0.28 TTD
%MW\p.2.c\0.0.13 IDC %MW\p.2.c\0.0.29 BRL
%MW\p.2.c\0.0.14 TDC %MW\p.2.c\0.0.30 IBR
%MW\p.2.c\0.0.15 FLG %MW\p.2.c\0.0.31 BRT
%MW\p.2.c\0.0.16 STA %MW\p.2.c\0.0.32 BEN
%MW\p.2.c\0.0.17 UFR %MW\p.2.c\0.0.33 BET
%MW\p.2.c\0.0.18 PFL %MW\p.2.c\0.0.34 1 FRT
%MW\p.2.c\0.0.19 SLP %MW\p.2.c\0.0.35 1 CLI
1 %MW\p.2.c\0.0.34 and %MW\p.2.c\0.0.35 are configuration parameters that are only
taken into account by the drive controller when it is stopped or on initial power up.
NOTE: This value will not be stored in the PLC unless the
SAVE_PARAM function is given prior to removal of power or
disconnection of the network.
Diagnostic Objects
PROGRAMMING THE PLC USING PL7 PRO SOFTWARE FOR THE ATV58 TRX
DRIVE CONTROLLER
FIPIO box
used logical
address
node
unused
logical
address
node
From the FIPIO Configuration dialog box in PL7 Pro software, open
the ATV58 module by double-clicking on it. The drive controller
configuration/adjustment window opens. See Figures 9 and 10.
You can assign a name in the Symbol column and define the symbol
names in PL7 Pro software using the %KW\p.2.c\0.0.0–0.0.15 object
types under Variables>I/O in the Application Browser. In the
Variables window make sure to select the drive controller from the
drop-down menu. For assignment instructions, use the PL7 Pro on-
line help.
If you choose not to have the PLC manage these drive controller
configuration parameters, check the Local configuration box (see
Figure 9). Selecting the Local configuration hides the Configuration
parameter list in PL7 Pro software, indicating that these parameters
will not be managed by the PLC. This requires that the drive controller
be manually configured using the keypad display or PowerSuite PC
software.
The drive controller's adjustment parameters are also available from
this window through the drop-down menu in the upper left-hand
NOTE: The operator keypad display takes priority over the terminals.
In serial link mode the speed reference and the start/stop control
cannot come from separate sources. That is, it is not possible to have
the speed reference sent across the serial link and the start/stop
control from the terminal strip.
For details on how to select between the two modes of local (hand)
control see the latest revision of the keypad display manual,
VVDED397047US.
When the communication network has control of the drive controller,
the setpoints and commands are controlled via the network and
cannot be modified by the terminals, the keypad display, or any
device connected to the RS-485 MODBUS serial port. To command
the drive controller by the terminals or the keypad display, forced
local must be enabled.
WARNING
UNINTENDED EQUIPMENT ACTION
When in serial link mode, all terminal inputs are ignored except
digital inputs configured as stop functions and the Forced Local
input.
Forced Local
WARNING
UNINTENDED EQUIPMENT ACTION
When in forced local mode, all commands from the communication
ports are ignored.
When the forced local logic input is not active (low), all control of the
drive controller is transferred to the network if the controller is wired
as shown in Figures 11 or 12. The only local (hand) controls that are
still monitored by the drive controller are the logic input assigned to
forced local and any input assigned to a drive stop function.
Examples include:
• the stop button on the keypad display module
• logic input one (LI1) which is assigned to the function STOP if the
drive controller is configured for 3-wire control
• any logic input assigned to the functions freewheel stop, DC
injection braking, and fast stop.
Hand/Off/Auto (HOA)
WARNING
LOSS OF CONTROL
The user must provide a Hand/Off/Auto switch with the following
functionality:
• In the Hand position, forced local mode must be enabled.
• In the Off position, all run terminal inputs must be disabled via
open circuit, and forced local mode must be enabled.
• In the Auto position, the run terminal inputs must be disabled via
open circuit, and forced local mode must be disabled.
Failure to follow this instruction can result in death or serious
injury.
When the control switch is in the auto position, all local run and start
commands to the drive controller must be removed. During power-
up, the drive controller defaults to local control mode. (See “Control
Scheme Overview” on page 31.) After the drive controller recovers
from a power up sequence (including such unplanned events as an
AC line power disturbance), it immediately responds to any local
controls that are active before the FIPIO communication board has
initialized and assumed control. This can result in unintended
equipment operation.
When the control switch is in the hand or off position, the drive
controller must be placed into the forced local mode. While it is
possible to stop the drive controller in the serial link mode by
activating one of the local stop commands (such as the keypad
display stop button), commands sent over the network can restart the
drive controller if it is not in forced local mode. See “Forced Local” on
page 32.
Refer to Figures 11 and 12 on page 34 for assistance in designing
Hand/Off/Auto control. For the run reverse and forced local functions,
select any unused logic inputs on the main control board. Assign a
logic input to the run reverse function only if appropriate for the
application.
NOTE: When the HOA switch is in the auto position, removing the
local run forward or run reverse commands does not stop the drive
controller.
+24
Stop Hand Off Auto
The cross hatch ×
LI1 Stop
under the selector
Fwd switch position
LI2 Run Forward indicates a closed
contact.
Rev
LIx Run Reverse
NOTE: When the HOA switch is in the auto position, removing the
local run forward or run reverse commands does not stop the drive
controller.
WARNING
UNINTENDED EQUIPMENT ACTION
Loss of communication will not cause the drive controller to fault
when bit 14 of Word 402 is set to 1.
INDEX
P
PLC 31
Symbols
%I registers 19, 22
%IW registers 19–21 R
%KW registers 18, 19, 21, 29 receiving 7
%MW registers 18, 19, 22–
26, 30
%QW registers 19–21 S
serial link mode 31
storage 7
A
animation table 24
C
cable
protection 14
cable routing 14–15
control
local and serial link 31–32
modes 31–35
control sources 31
E
electrical interference 14
F
fast serial link 31
forced local 33
FSD C8P 18–19
H
Hand/Off/Auto 33
handling 7
I
inspection 7
L
local and serial link control 31–
32
local control mode 31
91598275011101