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TeSys U Profibus DP
Quick Start Guide
06/2009

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www.schneider-electric.com

Schneider Electric assumes no responsibility for any errors that may appear in this document. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us. No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of Schneider Electric. All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer should perform repairs to components. When devices are used for applications with technical safety requirements, the relevant instructions must be followed. Failure to use Schneider Electric software or approved software with our hardware products may result in injury, harm, or improper operating results. Failure to observe this information can result in injury or equipment damage. 2009 Schneider Electric. All rights reserved.

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Table of Contents

About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Presentation of the Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Schneider Electric Solution with Tesys U Motor Starter. . . . . . . . . . . . . . . . . . . . . . . . . . .

4 5
5 6

Chapter 2 Setting Up TeSys U. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUCA12BL and LUCD18BL Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LULC07 Connectors, and Address Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9
9 10

Chapter 3 Setting Up Communication Network to a PLC . . . . . . . . . . . . . . . . . . . . . .

3.1 Configuring TeSys U on the Profibus DP Network with Unity Pro and Sycon. . . . . . . . . . . 3.2. Configuring DFBs with the Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11
12 18

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About the Book

At a Glance
Document Scope The Quick Start Guide uses an application example to describe the different steps to quickly install, configure, and control TeSys U motor starters. With this Quick Start Guide, you can easily set up a Profibus DP communication network, provided that you have a basic knowledge in PLCs and application software (Unity Pro, Sycon, ...). You do not need any other document to perform this task. For more details about other capabilities of TeSys U motor starters, consult the related documents listed below. Related Documents
Title of Documentation TeSys U LULC07 Profibus DP Communication Module - Users Manual TeSys U Communication Variables - Users Manual TeSys U LUB/LUS Starters - Instruction Sheet TeSys U LUCA/LUCB/LUCC/LUCD Control Units - Instruction Sheet TeSys DFB Offer - User Manual TeSys U LULC07 Profibus DP Communication Module - Beginners Guide TeSys U LULC07 Profibus DP Communication Module - Application Note Reference Number 1672610 1744082 1629984 AAV40503 1672600 1672611 1672612

You can download these technical publications and other technical information from our website at www.schneider-electric.com. User Comments We welcome your comments about this document. You can reach us by e-mail at techcomm@schneider-electric.com.

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Introduction 1672606 06/2009

Introduction

1
What's in this Chapter? This chapter contains the following topics:
Topic Presentation of the Application The Schneider Electric Solution with Tesys U Motor Starter Page 5 6

Presentation of the Application

Introduction The application example helps you to define Direct On Line (D.O.L.) motor starters step by step, in order to: provide thermal magnetic protection, control the motor, and obtain contactor feedback and circuit breaker trip feedback. Description of the Application Motor 1 (M1): 3-phase motor, class 10, 5.5 kW (7.5 hp) at 440 V, 50 Hz, rated current In = 10.5 A, D.O.L. Motor 2 (M2): 3-phase motor, class 20, 7.5 kW (10 hp) at 440 V, 50 Hz, rated current In = 14.7 A, D.O.L. with remote monitoring of motor load. Traditional Solution The scheme below shows wiring in the traditional solution: all control and feedback information is wired through a PLC.
Power Scheme Control Scheme

440 V 50 Hz Q1 Q2

KM1

KM2

M1 5.5 kW

M2 7.5 kW

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The Schneider Electric Solution with Tesys U Motor Starter

Power and Control Schemes in the Schneider Electric Solution
Power Scheme
440 V 50 Hz TeSys U Q1 KM1 Q2 KM2 TeSys U

Control Scheme

TeSys U

TeSys U

A1

A2

A1

A2

LUCAppBL

LUCDppBL

Modicon TSX
LU9GC7

2
LUCApp LUCDpp

LULC07 Profibus DP bus 24 Vdc

A1 A2 A1 A2

LULC07 Profibus DP bus 24 Vdc

Interface 1 PROFIBUS RS485

Interface 2 host

490 NAE 911 00

PROFIBUS-TAP

3
IN OUT

LULC07

LULC07

M1 5.5 kW 24 Vdc

M2 7.5 kW 24 Vdc

24V DC

1. TSX PBY 100 Profibus DP master coupler including a PCMCIA board, cable and a tap 2. LU9GC7 splitter box with 2 sub-D 9 connectors (bus connection to LULC07 module) and screw terminals (24 V) 3. LU9BN11L prewired coil connection

Control Units Used in the Schneider Electric Solution The Schneider Electric solution presented in this Quick Start Guide uses TeSys U to meet different client needs. LUCA12BL is a standard control unit used with motor 1 for basic needs: control a motor remotely (start/stop) provide status information (ready, running, fault condition) LUCD18BL is an advanced control unit used with motor 2 for advanced needs, in addition to the standard ones: warning automatic and remote reset via the bus indication of the motor load differentiation of faults

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Introduction

Architecture of the TeSys U System The following architecture describes the main components of the TeSys U system mounted on a plate:
1 2 3 4 5 6 7 8 9 10 11

12

13

14

15

17

16

Legend 1+2+3+4 1 2 3

Commercial Reference

Description Premium Programmable Logic Controller (PLC) including 3 modules: power supply (1), processor (2), and PCMCIA (3) on a rack (4)

TSX PSY 5500M TSX P57 354M TSX PBY 100

Premium power supply module Premium processor Premium PCMCIA module including: a host module for the PCMCIA board, a Profibus DP PCMCIA board with its integral connecting cable, 0.6 m (2 ft) long, and a 490 NAE 911 00 Profibus tap with 1 female sub-D 9 (left) connector and 1 male sub-D 15 (right) connector Premium single rack (6 positions), enabling all Premium modules to be mechanically and electrically fitted Connector 100 m (328 ft) cable, to be cut according to the network size Splitter box with 2 sub-D 9 connectors (bus connection) and screw terminals (24 V) TeSys U power base Standard control unit Profibus DP communication module with plug-in terminal block, for wire-towire control of A1/A2 terminals TeSys U power base Advanced control unit Connector for daisy chaining connection Slave 1 connector line termination = OFF Slave 2 connector line termination = ON 100 m (328 ft) cable, to be cut according to the network size Prewired coil connection (optional)

4 5 6 7 8 9

TSX RKY 6 490 NAD 911 03 (or 04) TSX PBSCA100 LU9GC7 LUB12 LUCA12BL

10, 13, 17 LULC07 11 12 14 LUB32 LUCD18BL LU9AD7

15 16

TSX PBS 100 LU9BN11L

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Introduction

Software Tools The following software tools must be used to set the applications. Their use requires a basic knowledge.
Commercial Reference UNY SPU EFP CD40 SYCSPULFUCD29M Freeware DFB library, including Ctrl_pfb_u_ms Description Unity Pro Extra Large V4.0 programming software for Premium PLC. Sycon V2.9 network configuration software for Premium PLC (single user license). TeSys U cyclic control/command for Profibus DP MS. Download the TeSys U DFB library from the www.schneider-electric.com website.

Network Conditions Protocol: Profibus DP Baud Rate: 1,500 kbps Addresses: 1 for TeSys U motor 1 2 for TeSys U motor 2 Fallback Strategy: In case of a communication loss with the PLC, the fallback strategy offers the possibility to operate a motor in different ways. Set parameter 682 to one of the following values:
Parameter 682 Value 0 1 Fallback Mode Disabled Frozen Description No strategy is applied. This is not recommended. On detection of a communication loss, the motor will keep its status: If running, the motor will keep running. If stopped, the motor will remain stopped. No change in control status is authorized. A new control will be considered only after a communication loss reset (703.3). 2 Forced stop (default value) Unchanged The motor is forced to stop. Output OA1 = 0 Output OA3 = 0 Changes in control status are authorized. A new control will be considered even before a communication loss reset (703.3).

3 4 5

Forced to run forward Output OA1 = 1 (direct) Output OA3 = 0 Forced to run reverse Output OA1 = 0 Output OA3 = 1 (reversing)

The fallback strategy adapted to the application is: Value 1 = Frozen for motor 1 Value 2 = Forced stop for motor 2

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Setting Up TeSys U

2
What's in this Chapter? This chapter contains the following topics:
Topic LUCA12BL and LUCD18BL Settings LULC07 Connectors, and Address Settings Page 9 10

LUCA12BL and LUCD18BL Settings

Setting Current on the Control Units The figure below shows how to set current on the control unit using a screwdriver (LUCA12BL here):

LUCA / LUCD
ys TeS 12BL A LUC 24V c

4.00A 3.00A 12.0A 9.00A 5.00A 7.00A

CLA 3a

SS 1

LULC07

Current Setting Values The table below shows the settings for LUCA12BL (Standard Control Unit) and LUCD18BL (Advanced Control Unit):
Control Unit LUCA12BL LUCD18BL Motor M1 M2 Current Setting Range 3..12 A 4.4..18 A Motor Nominal Power 5.5 kW (7.5 hp) 7.5 kW (10 hp) Current Setting Value = Motor Rated Current 10.5 A 14.7 A

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LULC07 Connectors, and Address Settings

Presentation Use the DIP switches, under the LULC07 communication module, to set the Profibus DP address.
1
RxD/TxD-P CNTR-P M24 DGND

VP P24

RxD/TxD-N

24V c

LI2 LI1 LO1

1 2 3

Profibus DP sub-D 9 connector Input/Output terminal block and 24 Vdc Address

Address Assign an address from 1 to 127, using the 7 right most switches (SW1 to SW7). Address 0 (zero) is not allowed and is considered an invalid configuration. In the application, addresses are 1 and 2:
SW7 0 0 SW6 0 0 SW5 0 0 SW4 0 0 SW3 0 0 SW2 0 1 SW1 1 0 Address 1 (default value) 2

Address 1 for TeSys U Motor 1

SW7 SW6 SW5 SW4 SW3 SW2 SW1 on off

Address 2 for TeSys U Motor 2

SW7 SW6 SW5 SW4 SW3 SW2 SW1 on off

10

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Setting Up Communication Network to a PLC 1672606 06/2009

Setting Up Communication Network to a PLC

3
Introduction This chapter describes how to set communication to a Premium PLC step by step, using: Unity Pro, and Sycon. What's in this Chapter? This chapter contains the following topics:
Topic 3.1 Configuring TeSys U on the Profibus DP Network with Unity Pro and Sycon 3.2. Configuring DFBs with the Application Page 12 18

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Setting Up Communication Network to a PLC

3.1 Configuring TeSys U on the Profibus DP Network with Unity Pro and Sycon
Configuration Process for a Premium PLC

1) Downloading the GSD Files The following table describes the steps to follow to download the GSD and icon files associated to Tesys U from the www.schneider-electric.com website:
Step 1 2 3 4 Action Open the Schneider Electric website: www.schneider-electric.com. Click Products and Services, and then click Automation and Control. In the Downloads section of the left menu bar, click Current offers. In the Choose a function drop-down list, select Motor Control. In the Choose a range drop-down list, select TeSys U. In the Choose a type of document drop-down list, select Software/Firmware. Click >Find. 5 6 Select Communication Module TeSys U PROFIBUS LULC07 and download LULC07_GSD_DIB_files_V100.exe file. Double-click LULC07_GSD_DIB_files_V100.exe on your hard disk. Click Accept in the Licence for software downloaded from Schneider-Electric web sites window which opens, and then browse for a destination folder and click Install. Select the GSD file: TELE094C.GSD

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2) Configuring the Application Network The first configuration steps with Unity Pro XL software are described below:
Step 1 2 Action Start Unity Pro XL V4.0 software. Configure your Premium PLC and communication accessories (PCMCIA card, etc.):

3 4

Save your application as an .STU file. Double-click the TSX PBY 100 coupler. The PROFIBUS-DP MODULE Configuration window opens:

You may not need to edit it. To continue the configuration process, click on the Sycon (hilscher) button. If it is not displayed, install Sycon software again.

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Setting Up Communication Network to a PLC

Continue the configuration process with Sycon software, as described below:

Step 1 2 3 4 5 Action In Sycon V2.9 software, click File New. In the Select fieldbus dialog, choose Profibus DP and validate. Import your LULC07 GSD file by clicking File Copy GSD. Browse until you find the TELE094C.GSD file. Insert a master: click Insert Master..., or

select 6 Double-click the Setting menu and select Master Configuration: the Auto addressing box is default checked. It means that you will not have to edit the input and output addresses for nodes 1 and 2. If you uncheck the box, you will have to edit the node addresses. In the Insert Master window, select TSX PBY 100 from the Available masters list. Click the Add>> button. Enter an address in Station address, e.g. 10.

Confirm with OK. 7 Insert a node: click Insert Slave..., or

select 8 In the Insert Slave window, select LULC07 - TeSys U Profibus from the Available slaves list:

Slave 1 is at address 1. Slave 2 is at address 2. 9 To set the bus parameter, select the master on screen, and then click Settings Bus Parameter:

Select the Baudrate at 1500 kBits/s and confirm with OK.

14

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Step 10

Action Double-click a node to open the Slave Configuration window:

From the Module list, select: Sc_St_R_MS for Slave1 Sc_Ad_R_MS for Slave2 Where abbreviations stand for... Sc: Starter-controller, St: Standard control unit, and Ad: Advanced control unit, R: Remote control, MS: Motor Starter. NOTE: To shift from Slave1 to Slave2, you can either do it from this window, changing slaves in the Actual slave box, or go to the tree structure and double-click Slave2. 11 To define a communication loss fallback strategy, click the Parameter Data button. In the Parameter Data window, click the Module button. Select the first line of the list and set the communication loss fallback strategy from the drop-down list:

Freeze outputs for slave 1 Force stop for slave 2 Confirm with OK. 12 Save your configuration by clicking File Save as. Your configuration file will have a .PB extension. Convert your file to an ASCII format by clicking File Export ASCII, for use in Unity Pro. Quit Sycon software.

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Setting Up Communication Network to a PLC

Complete the configuration process with Unity Pro XL software, in the PROFIBUS-DP MODULE Configuration window:
Step 1 Action NOTE: In the Configuration window, (1), (2) and (3) correspond to actions to perform in steps 1, 2, and 3.

Click the Load CNF button and open the .CNF file. 2 Change the default Diagnostic Length, along with the Diagnostic Telegram for Profibus DP information contained in TeSys U LULC07 Profibus DP Users Manual: Default value (in bytes) = 32 New value = 36 To optimize the memory size, set the No. of IW/QW from the drop-down list: Default value = 128 New value = 32 Select Edit Validate, or click Select Build Rebuild all project. to validate the configuration.

4 5

16

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3) Performing Functional Testing of the Communication Network Including Premium PLC and Products
Step 1 2 3 4 5 Action Connect the appropriate programming cable from your PC to the Premium PLC. Power up the Premium PLC. Click Connect. From the PLC menu, transfer the project. Power up the 2 TeSys U systems, and then click Run. At that stage, the communication is established correctly: red BF communication status LED is off, and green 24V LED is on. However, if the red ERR fault LED is blinking, it means that the communication has been lost. The PROFIBUS-DP MODULE window has a Debug tab. The tables below are extracted from this tab, with the addresses containing the cyclic exchanges per equipment. Name the variables in such a way to avoid programming with names which do no provide any information on the contents of the memory location (e.g. Ready_M1 instead of %IW0.3.0).

In case of a communication fault at a slaves level, the corresponding line in the PROFIBUS-DP slave configuration list displays in red, and an explanation message appears in the PROFIBUS-DP diagnostic box. Cyclically exchanged data appears in the Value column.

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Setting Up Communication Network to a PLC

3.2. Configuring DFBs with the Application

Presentation The TeSys DFB (Derived Function Blocks) offer has been developed to simplify and optimize the integration of TeSys U starter-controllers in PLC applications. The Ctrl_pfb_u_ms DFB is dedicated to the control and command of a single TeSys U starter-controller (up to 32 A/15 kW or 20 hp) through the Profibus DP MS (Motor Starter) network. 1. Downloading the DFB Files 2. Installing DFB in Unity Pro 3. Fetching Your Project and DFB Application in Unity Pro For more information, see the TeSys DFB Offer User manual. 1) Downloading the DFB Files The following table describes the steps to follow to download the TeSys DFB offer from the www.schneider-electric.com website:
Step 1 2 3 4 Action Open the Schneider Electric website: www.schneider-electric.com Click Products and Services, and then click Automation and Control. In the Downloads section of the left menu bar, click Current offers In the Choose a function drop-down list, select Motor Control. In the Choose a range drop-down list, select TeSys U. In the Choose a type of document drop-down list, select Software/Firmware. Click >Find. 5 6 Select TeSys DFB offer package and download the zip file on your hard disk. Extract the TeSys DFB offer package.zip file content to a single directory on your hard disk. 2 directories, PL7 Pro and Unity Pro, will be created, each of them containing the following folders:

2) Installing DFB in Unity Pro

Step 1 Action From Start button, All Programs menu, browse to Schneider Electric Unity Pro Types Library Update. In the Types Library Update window, browse to 04 Cyclic control command FAMILY.DSC and open it. NOTE: The application version you select must be compliant with Unity Pro. Click the Install family button. A pop-up window appears, with the following message: The installation has succeeded. Then, exit.

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3) Fetching Your Project and DFB Application in Unity Pro

Step 1 2 Action Start Unity Pro software. Open the FBD section of a program. From Edit menu, get Data Selection... sub-menu. An empty Function Input Assistant window opens. First item is FFB type. Browse to get the Profibus DFB: Ctrl_pfb_u_ms. The following window opens:

Confirm with OK. 3 The Function Input Assistant window now displays your selection:

Confirm with OK. 4 The DFB graphical representation is displayed:

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Setting Up Communication Network to a PLC

Input Characteristics The following table describes the DFB inputs and their availability according to the control unit:
Input Ms_in1 Run_fwd Run_rev Rst_flt Type INT Range _ Default Value Description 0 0 0 0 To link to the first word of the MS Profibus slave input cyclic data Motor run forward command Motor run reverse command Reset fault (in case of a communication module internal fault, Reset fault resets the communication module to factory settings) LUCA LUCD

EBOOL 0...1 EBOOL 0...1 EBOOL 0...1

Rst_warn EBOOL 0...1 Em_strt Trip_tst EBOOL 0...1 EBOOL 0...1

0 0 0

Reset warning (for example, communication loss) Emergency start (resets the thermal memory) Overcurrent trip test via communication bus

Output Characteristics The following table describes the DFB outputs and their availability according to the control unit:
Output Ms_out1 Ready Closed Tripped Fault Alarm Rst_auth Starting Type INT Range _ Default Value Description 0 0 0 0 0 0 0 0 To link to the first word of the MS Profibus slave output cyclic data System ready: the rotary handle is turned to the On position and no faults detected Pole status: closed System tripped: the rotary handle is turned to Trip position All faults All warnings Fault reset authorized Start-up in progress: 1 = ascending current is greater than 10 % FLA 0 = descending current is lower than 150 % FLA Motor running with detection of current, if greater than 10 % FLA Average motor current (% FLA) LUCA LUCD

EBOOL 0...1 EBOOL 0...1 EBOOL 0...1 EBOOL 0...1 EBOOL 0...1 EBOOL 0...1 EBOOL 0...1

Running Avg_curr

EBOOL 0...1 INT 0...200

0 0

20

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Programming DFB (= M1) for Motor 1

Step 1 2 Action Link the Run_fwd input to the motor 1 start condition. Link the M1 outputs to PLC variables for use in the program: Closed M1 output = position of the KM1 contactor Tripped M1 output = tripped position of the Q1 TeSys U Check that M1, for Motor 1, displays as follows:

1 2

Not applicable Applicable but not used; can be managed by the PLC application

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Setting Up Communication Network to a PLC

Programming DFB (= M2) for Motor 2

Step 1 2 Action Link the Run_fwd M2 input to the motor 2 start condition. Link the M2 outputs to PLC variables for use in the program: Closed M2 output = position of the KM2 contactor Tripped M2 output = tripped position of the Q2 TeSys U Link the Avg_curr M2 output to a PLC register for use of motor 2 average current in the program. Check that M 2, for Motor 2, displays as follows:

3 4

1 2

Not applicable Applicable but not used; can be managed by the PLC application

22

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