Installation And Start-up Guide RS485 And RS232 Adapter .
Installation andStart-up GuideRS485 and RS232 Adapterfor product type ACS 140
ACS 140RS485 and RS232 AdapterInstallation and Start-upGuide3AFY 61492828 R0125 REV AENEffective: 1.10.1998 1998 ABB Industry Oy. All rights reserved.
Safety InstructionsOverviewThis chapter states the safety instructions that must be followed wheninstalling and operating the RS485/RS232 adapter. If neglected, physicalinjury and death may follow, or damage may occur to the frequency converter,the motor and driven equipment. The material in this chapter must be studiedbefore attempting any work on, or with, the unit.WarningsWarnings are used to inform of conditions which can, if proper steps are nottaken, lead to a serious fault condition, physical injury and death.Readers are informed of situations that can result in serious physical injuryand/or serious damage to equipment with the following symbols:Dangerous Voltage Warning: warns of situations in which a highvoltage can cause physical injury and/or damage equipment. Thetext next to this symbol describes ways to avoid the danger.General Warning: warns of situations which can cause physicalinjury and/or damage equipment by means other than electrical. Thetext next to this symbol describes ways to avoid the danger.iii
General Safety InstructionsWARNING! All electrical installation and maintenance work on theACS 140 should be carried out by qualified electricians.The ACS 140 and adjoining equipment must be properly earthed.Do not attempt any work on a powered ACS 140. After switching off themains, always allow the intermediate circuit capacitors 5 minutes to dischargebefore working on the frequency converter, the motor or the motor cable. It isgood practice to check (with a voltage indicating instrument) that thefrequency converter is in fact discharged before beginning work.The ACS 140 motor cable terminals are at a dangerously high voltage whenmains power is applied, regardless of motor operation.There can be dangerous voltages inside the ACS 140 from external controlcircuits when the ACS 140 mains power is shut off. Exercise appropriate carewhen working with the unit. Neglecting these instructions can cause physicalinjury and death.WARNING! There are several automatic reset functions in the ACS 140.If selected, they reset the unit and resume operation after a fault. Thesefunctions should not be selected if other equipment is not compatible with thiskind of operation, or dangerous situations can be caused by such action.Because of the variety of uses for this equipment and because of thedifferences between this solid-state equipment and electromechanicalequipment, the user of and those responsible for applying this equipmentmust satisfy themselves as to the acceptability of each application and use ofthe equipment. In no event will ABB be responsible or liable for indirect orconsequential damages resulting from the use or application of thisequipment.iv
Table of ContentsSafety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiOverview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiWarnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiGeneral Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ivChapter 1 – Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Delivery Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1How to Use This Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Conventions Used in This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Using the Adapter with ACS 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Chapter 2 – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Selecting the Communication Speed . . . . . . . . . . . . . . . . . . . . . . . . . 4Selecting RS485 or RS232 Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5RS485 Bus Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Installation to RS485 Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Installation to RS232 Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Earthing and Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Chapter 3 – Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Communication Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Control Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Diagnostic Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Chapter 4 – Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Introduction to Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Register Read and Write . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Register Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Exception Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Function Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23The Command Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25The Status Word. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Actual Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Fault and Alarm Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Chapter 5 – Fault Tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Appendix – Parameter Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . 33Effect of Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Signed Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33v
vi
INTRODUCTIONChapter 1 – IntroductionOverviewThe RS485 and RS232 adapter is used for connecting the ACS 140frequency converter to a serial Modbus (RS232 or RS485) network. Theadapter can also be used with the ACS 400 frequency converter.Delivery CheckThe option package includes: RS485/RS232 Adapter Installation and Start-up Guide for RS485 and RS232 AdapterHow to Use This GuideThe purpose of this Guide is to provide the information necessary to install,commission, use, and to fault diagnose the adapter.Safety Instructions describe the formats for warnings and notations usedwithin this guide. This chapter also states the safety instructions which applyto the installation and operation of the RS485/RS232 Adapter.Chapter 1 – Introduction, the chapter you are reading now, contains a shortdescription of this manual and a list of related publications.Chapter 2 – Installation contains instructions for mechanical and electricalinstallation of the adapter.Chapter 3 – Programming explains how to program the ACS 140 drive forModbus communication, and what additional parameters are available withthe module.Chapter 4 – Communication describes the Modbus communication onACS 140 drives.Chapter 5 – Fault Tracing describes how to diagnose the most commonproblems with the adapter.Appendix – Parameter Scaling contains a complete list of all the parameters,their 4xxxx register addresses, and the scaling accessible through theModbus network.1
Conventions Used in This GuideThis manual uses some terms and conventions which might not be known toevery user of this manual. Some of these terms are described below.4XXXX Register AreaModicon PLCs have a signed integer data table area, which is used forAnalogue Output modules and for storing temporary or set-point values.These registers are in the address area starting from 40001. The last registeraddress available on PLCs depends on the available memory, but is lessthan 49999.The ACS 140 drive simulates this area by providing a read and write accessto its parameters through this register address area.Related PublicationsACS 140 Programming Guide.Using the Adapter with ACS 400The RS485 and RS 232 adapter can also be used with the ACS 400frequency converter.The ACS 400 frequency converter has two serial ports or channels asstandard: RS485 connection (Channel 1) and serial port for the control panel(Channel 0). Normally when Modbus control is desired, Channel 1 is used.Channel 0 can be used to connect the DriveWindow Light PC tool. In thiscase, the control panel is replaced by the adapter.When using the adapter with the ACS 400 and DriveWindow Light, note thefollowing: There is no need to set any ACS 400 parameters: Channel 0communication settings cannot be modified. Communication settings forChannel 0 are given in Table 2 on page 11. The contents of this guide need to be observed only to the extent that isneeded to set up the DIP switches and jumpers of the adapter (Chapter 2– Installation).2
Chapter 2 – InstallationThis chapter contains instructions for setting up the RS485/RS232 adapter.WARNING! Verify that the ACS 140 is not powered before starting theinstallation.The adapter operates either in RS232 mode or RS485 mode. The mode canbe selected with a jumper. By default, the adapter operates in RS485 modeat a communication speed of 9600 bps (bits per second).Remove the front cover to access the configuration switches and jumpers.LEDs:RxDTxDPowerRS485 terminal X23 (A)RS232/RS485 modeselection jumper S52 (C)1 (B)RS485 bus terminationjumper S2 and S3ON3 (A)1 2 32 (C)1 (B)Communicationspeed settingDIP switch S1RS485 terminal X3RS232 terminal X4Figure 1Connectors and switches.3INSTALLATIONOverview
MountingThe adapter replaces the optional ACS100-PAN control panel. To eliminatethe stress caused by the cables, use a strain relief.Selecting the Communication SpeedCommunication speed is selected by DIP switch S1 and by parameter 5201COMM SPEED. The factory setting for the communication speed is 9600 bps(bits per second).Communication speed setting using DIP switch S1 is needed only when theadapter operates in RS485 mode.DIP switch S1ONCommunication speed300 bps ON600 bps ON1200 bps ON2400 bps ON4800 bps ON9600 bps ON19200 bps Figure 24Selecting the communication speed for the adapter.
Selecting RS485 or RS232 ModeThe adapter operates either in RS232 mode or in RS485 mode, selectable bya jumper. As a factory setting, the adapter operates in RS485 mode.Jumper S5ModeS51INSTALLATIONRS485RS2322Figure 3Selecting the operating mode.RS485 Bus TerminationThe RS485 bus must be terminated using 120 Ω resistors at both ends of thenetwork. The adapter has built-in termination resistors that can be enabled byjumpers S2 and S3. Refer to “Earthing and Termination” on page 10. Bydefault, bus termination is enabled.Both jumpers S2 and S3 must beconnected in order to obtain 120 Ω.S2Jumper S2S3Jumper S3If no termination is needed, both jumpers S2 and S3 must be opened.Figure 4Selecting RS485 termination impedance.5
Installation to RS485 Bus1Make sure power is not connected to the ACS140.2Connect the ACS100-PAN control panel to the drive.3Connect power to ACS140.4Set up communication: station number, communication speed of theACS 140 and parity. Refer to Chapter 3 – Programming.5Set up other drive parameters as needed. Refer to ACS140 ProgrammingGuide and chapter 3 of this manual.6Disconnect power from the ACS140.7Set communication speed of the adapter with DIP switch S1.8Confirm that the operation mode is RS485 (jumper S5).9If the termination is not needed, remove jumpers S2 and S3 to disable it.10 Connect the adapter to the ACS 140 and wire it to the RS485 network.Skip steps 2-6 if the default parameter settings of the ACS 140 can be used.WiringThe RS485 link is a daisy-chained bus, without dropout lines. The RS485 linkshould also be terminated on both physical ends of the wire to reduce thenoise on the network.Modbus network should be wired using Belden 9841 or equivalent. Belden9841 is a single twisted shielded pair cable with a wave impedance of 120 Ω.The network should be connected according to Figure 5 below. Theconnection of both the incoming and outgoing cables to the same terminalenables the disconnection of the module without disturbing thecommunication between other stations.6
ABINSTALLATION2.2 nFC1 MΩFigure 5 RS485 wiring. The cable shield can be left unearthed. Signal C(common) is connected to ACS 140 chassis through 1 MΩ impedance.Table 1 RS485 connection terminals. Terminals X2 and X3 are connected inparallel.X2, X3Description1BData2CCommon3AData3 (A)RS485 terminal X22 (C)1 (B)3 (A)RS485 terminal X32 (C)1 (B)Figure 6RS485 connection terminals X2 and X3.7
Installation to RS232 Bus1Make sure power is not connected to the ACS140.2Connect the ACS100-PAN control panel into the drive.3Connect power to ACS140.4Set up communication: station number, communication speed of theACS 140 and parity. See Chapter 3 – Programming.5Set up other drive parameters as needed. Refer to ACS140 ProgrammingGuide and chapter 3 of this manual.6Disconnect power from the ACS140.7Set the operation mode of the adapter to RS232 with jumper S4.8Connect the adapter to the ACS 140. Connect the RS232 cable.Skip steps 2-6 if the default parameter setting of the ACS 140 can be used.WiringRS232 bus is a point-to-point type bus. Typical usage is to connect the driveinto the serial port of a PC.The maximum RS232 cable length is 3 metres. The RS232 cable is notincluded in the delivery.8
ABBPCAC 140INSTALLATIONserial portmax. length 3 mFigure 7RS232 D6DSR7RTS8CTS9NCFigure 8 RS232 signals. DTR and DSR as well as RTS and CTS signals areinternally connected. The RS232 cable should not have TxD and RxD signalsconnected across.9
Earthing and TerminationRS485 BusThe RS485 network should not be directly earthed at any point. All thedevices on the network should be well earthed using their correspondingearthing terminals.As always, the earthing wires should not form any closed loops, and all thedevices should be earthed to a common earth.The RS485 network must be terminated using 120 Ω resistors at both ends ofthe network as shown in Figure 9. These resistors are already resident on theadapter. Use jumpers S2 and S3 to connect the termination resistors.TerminatedFigure 9TerminatedTermination for the RS485 link.The connections may only be made with the drive disconnected fromthe power source.10
Chapter 3 – ProgrammingThis chapter describes how to program the ACS 140 drive for Modbuscommunication.The reader should be already familiar with programming thedrive parameters using the ACS 100 - PAN control panel, and the way theparameters are arranged in groups. For details, see the ACS 140Programming Guide.GeneralWhen the ACS 100 - PAN control panel is attached to the drive, the panelcommunicates using the Modbus protocol and the settings given in Table 2.If the panel (or any other master that uses communication setting shown inTable 2) is NOT detected in 4 seconds after power up, the ACS 140 will setup Modbus communication normally, using the parameters 5201 STATION ID,5202 COMM SPEED and 5203 PARITY. This communication setting is then useduntil the next power-down.Note! If any of the parameters 5201 STATION ID, 5202 COMM SPEED and 5203PARITY has been altered, the control panel will operate only if it is connectedbefore the power is applied to the ACS 140 (or immediately after power-up).Note! If any of the parameters 5201 STATION ID, 5202 COMM SPEED and 5203PARITY is altered, the modification takes effect only on the next power-up, andif the ACS 100 - PAN control panel is not connected when the power isapplied.Table 2 ACS 140 (ACS 400) default communication settings.Station numberCommunicationspeedParity bitStop bits19600 bpsnonetwo11PROGRAMMINGWhen power is connected, the ACS 140 will automatically check for thepresence of the panel. If the panel is detected, the ACS 140 will set up theModbus communication using the default settings shown in Table 2. Thiscommunication setting is then used until the next power down.
Communication SettingsThe configuration information is in Group 52. The contents of this group areshown in Table 3 below.Table 3 Communication parameters.CodeNameRangeDefaultGroup 52SERIAL COMM5201STATION NUMBER1 - 24715202COMM SPEED3 300 bps6 600 bps12 1200 bps24 2400 bps48 4800 bps96 9600 bps192 19200 bps96 (9600 bps)0 (NONE)5203PARITY0-25204COMM FAULT TIME0.1 - 60.0 s1.0 s5205COMM FAULT FUNC0-30 (NOT SEL)12User
CodeName5201STATION NUMBERSets the slave number for the ACS 140 in Modbus network.Range: 1 - 247Note! Modifications take effect only on the next power up.5202COMM SPEEDDefines the communication speed of the ACS 140 in bits per second (bps).3 300 bps48 4800 bps6 600 bps96 9600 bps12 1200 bps192 19200 bps24 2400 bpsNote! Modifications take effect only on the next power-up.PARITYDefines the parity to be used in Modbus communication. Parameter alsodefines the number of stop bits. In Modbus communication, the number of stopbits is 2 with no parity bit, and 1 with even or odd parity.0 NONE1 EVEN2 ODDNote! Modifications take effect only on the next power-up.5204COMM FAULT TIMETime limit for communication loss detection. This parameter is used togetherwith parameter 5205 COMM FAULT FUNC to define the ACS 140 operation whenthe communication with the master device in the Modbus network is lost.The master device in the Modbus network must signal its presence to everyslave device (ACS 140) in the network by periodically writing Command Word,External Reference 1 or External Reference 2 to each ACS 140 in the network.Maximum write period is set by this parameter.Range: 0.1 - 60.0 sNote! During the first 4 seconds after power-up, communication fault is notevaluated to compensate for possible long system start-up delay.5205COMM FAULT FUNCOperation in case the communication with the master device is lost. The timelimit for communication loss detection is set by parameter 5204 COMM FAULTTIME.0 NOT SELCommunication loss is not detected.1 FAULTA fault indication is shown on the control panel display and included in theStatus Word. The ACS 140 coasts to stop.2 CONST SPEED 7A warning indication is shown on the control panel display and included in theStatus Word. The speed reverts to the level set by parameter 1208 CONSTSPEED 7.3 REFERENCEA warning indication is shown on the control panel display and included in theStatus Word. The speed reverts to the level set by the current frequencyreference.Warning! If CONST SPEED 7 or REFERENCE is selected, ensure it is safe tocontinue operation in case communication with the master device fails.13PROGRAMMING5203
Control LocationsThe ACS 140 drive can receive control information from multiple sources,including discrete I/O, analogue I/O, keypad, and serial communicationchannel.To control the ACS 140 via the serial communication, it must beparameterised to accept control commands and/or frequency references fromthe serial communication channel. In addition, ACS 140 must be in remotecontrol.Table 4 Parameters for selecting control location.Code NameR
Communication speed is selected by DIP switch S1 and by parameter 5201 COMM SPEED. The factory setting for the communication speed is 9600 bps (bits per second). Communication speed setting using DIP switch S1 is needed only when the adapter operates in RS485 mode. Figure 2 Selecting
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5.3. STAFInst Uninstall 6. Platform Installation Notes 6.1. Linux installation 6.2. AIX installation 6.3. HP-UX IA64 64-bit installation 6.4. IBM i 32-bit (previously known as i5/OS or OS/400) installation 6.5. z/OS installation 6.6. FreeBSD installation 6.7. Mac OS X installation 6.8. Solaris installation 7. Environment Variable Settings 7.1.
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