Siemens Robicon NXG TOOLSUITE SOFTWARE USER MANUAL
Siemens Robicon NXG TOOLSUITE SOFTWARE USER MANUAL
Manual Number: 902291
Version 3.0
January 2007
Siemens Energy & Automation, Inc. Large Drives A
500 Hunt Valley Road, New Kensington, PA, USA, 15068
Phone: 724-339-9500 Customer Support Phone: 724-339-9501 (24-hours)
Fax: 724-339-9562 Customer Support Fax: 724-339-9507
Web: www.siemens.com Customer Support E-mail: [email protected]
NXG TOOLSUITE
SOFTWARE
USER MANUAL
https://www.robiconperfectharmony.com/
For the support representative nearest you, please call Siemens main office at 724.339.9500.
Version History
© 2007 by s. No portion of this document may be reproduced either mechanically or electronically without the prior consent of s LD A
Version 1.0 (original) June 2006
Version 2.0 August 2006
Version 3.0 January 2007
NXG ToolSuite Software User Manual Table of Contents
Table of Contents
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Safety Precautions and Warnings.................................................................................... v
About This Manual .........................................................................................................vii
Separation of Manuals...........................................................................................vii
Reference Tools.....................................................................................................vii
Conventions Used in this Manual ........................................................................viii
Chapter 1: NXG ToolSuite Overview...........................................................................1-1
Overview ..............................................................................................................1-1
Chapter 2: NXG Drive Tool ..........................................................................................2-1
Drive Configuration Features...............................................................................2-1
Drive Variable Graphing Features .......................................................................2-1
Drive Status Features............................................................................................2-2
Drive Control Features .........................................................................................2-2
Drive Tool Pull Down Menu Features..........................................................2-2
Starting and Configuring the Drive Tool .............................................................2-4
Setting Up Ethernet (TCP/IP) Communications ..................................................2-5
Operating the Drive Tool ....................................................................................2-7
Fault and Alarm Displays..............................................................................2-7
Graphing Display ..........................................................................................2-9
Time Scale Adjustment...............................................................................2-13
Freezing Graph on Fault..............................................................................2-13
Freezing Graph on Trigger..........................................................................2-14
Post Processing of Data...............................................................................2-14
Chapter 3: NXG Debug Tool.........................................................................................3-1
System Requirements...........................................................................................3-1
Starting and Configuring the Debug Tool............................................................3-1
Operating the Debug Tool....................................................................................3-2
Chapter 4: NXG SOP Utilities ......................................................................................4-1
Introduction ..........................................................................................................4-1
SOP Utility Tool Overview..................................................................................4-1
Starting the SOP Utility Tool ...............................................................................4-4
SOP Development Process...................................................................................4-6
Overview of the Compile Process........................................................................4-7
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Input Source File.................................................................................................. 4-9
System Type Identification......................................................................... 4-11
SOP Source File.......................................................................................... 4-13
Input Flags .................................................................................................. 4-16
Output Flags ............................................................................................... 4-16
Redefining Flag Names .............................................................................. 4-17
Compiler Operation ........................................................................................... 4-18
Output Hex File ................................................................................................. 4-19
Downloading a System Program (Hex File)...................................................... 4-19
Siemens LD A SOP Upload/Download Utility Method............................. 4-20
Terminal Emulation Method....................................................................... 4-21
Termination................................................................................................. 4-21
Uploading a System Program (Hex File)........................................................... 4-25
Reverse Compiler .............................................................................................. 4-25
Header................................................................................................................ 4-32
Combined Source / Hex File.............................................................................. 4-35
Chapter 5: NXG Configuration Update Utility Overview ......................................... 5-1
System Requirements .......................................................................................... 5-1
Starting and Configuring the Configuration Update Utility ................................ 5-1
Features Overview ............................................................................................... 5-2
Copy Setup Files to Another Directory ........................................................ 5-2
Update Flash Disk Files................................................................................ 5-4
Make Bootable Default Disk Procedure....................................................... 5-4
Copy Files from Flash Disk to PC................................................................ 5-6
Make Bootable Copied Disk Procedure ....................................................... 5-6
Update ToolSuite Host Files on PC.............................................................. 5-8
Appendix A: Operators and Precedence .................................................................... A-1
Operators and Precedence................................................................................... A-1
Ladder Logic Translation.................................................................................... A-4
Appendix B: Ethernet Connections..............................................................................B-1
Direct Connection ................................................................................................B-1
Required for a Single Ethernet Direct Connection.......................................B-1
Required for a Single PC Multiple Drive Ethernet Connection Support......B-1
Configuring a PC to Work with a Direct Connection...................................B-2
Troubleshooting the Network Interface...............................................................B-5
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Changing Existing Network Configuration ................................................. B-5
Resolving Conflict in Network Interface..................................................... B-6
Removing Duplicate or Multiple Occurrences in Device Manager............. B-7
Appendix C: Glossary................................................................................................... C-1
Appendix D: Abbreviations.......................................................................................... D-1
NOTES ........................................................................................................................... N-1
Reader Comments Form .............................................................................................. R-1
Startup/Warranty Registration and Service Solutions............................................. W-1
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NXG ToolSuite Software User Manual Safety Precautions and Warnings
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The Perfect Harmony Variable Frequency Drives are designed with considerable thought to personal safety.
However, as with any piece of high power equipment, there are numerous internal connections that present
potentially lethal voltages. In addition, some internal components are thermally hot to the touch. Follow the warnings
below when working in or near the system.
Safety Precautions and Warnings
Danger - Electrical Hazards!
• Always follow the proper lock-out/tag-out procedures before beginning any maintenance or troubleshooting work on the drive.
• Always follow standard safety precautions and local codes during installation of external wiring. Protective separation must be kept between extra low voltage (ELV) wiring and any other wiring as specified in IEC61800-5-1.
• Always work with one hand, wear insulated or rubber safety shoes, and wear safety glasses. Also,
always work with another person present.
• Always use extreme caution when handling or measuring components that are inside the enclosure. Be
careful to prevent meter leads from shorting together or from touching other terminals.
• Use only instrumentation (e.g., meters, oscilloscopes, etc.) intended for high voltage measurements
(that is, isolation is provided inside the instrument, not provided by isolating the chassis ground of the
instrument).
• Never assume that switching off the input disconnect will remove all voltage from internal components. Voltage is still present on the terminals of the input disconnect. Also, there may be voltages
present that are applied from other external sources.
• Never touch anything within the cabinets until verifying that it is neither thermally hot nor electrically
alive.
• Never remove safety shields (marked with a HIGH VOLTAGE sign) or attempt to measure points
beneath the shields.
• Never run the drive with cabinet doors open. The only exception is the control cabinet which contains
extra low voltages (ELV).
• Never connect any grounded (i.e., non-isolated) meters or oscilloscopes to the system.
• Never connect or disconnect any meters, wiring, or printed circuit boards while the drive is energized.
• Never defeat the instrument’s grounding.
• Only qualified individuals should install, operate, troubleshoot, and maintain this drive. A qualified
individual is “one familiar with the construction and operation of the equipment and the hazards
involved.”
• Hazardous voltages may still exist within the cabinets even when the disconnect switch is open (off)
and the supply power is shut off.
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Additional safety precautions and warnings appear throughout this manual. These important messages should be
followed to reduce the risk of personal injury or equipment damage.
∇ ∇ ∇
Warning!
• Always comply with local codes and requirements if disposal of failed components is
necessary (for example, CPU battery, capacitors, etc.).
• Always ensure the use of an even and flat truck bed to transport the drive system. Before unloading,
be sure that the concrete pad is level for storage and permanent positioning.
• Always confirm proper tonnage ratings of cranes, cables, and hooks when lifting the
drive system. Dropping the cabinet or lowering it too quickly could damage the unit.
• Never disconnect control power while medium voltage is energized. This could cause
severe system overheating and/or damage.
• Never store flammable material in, on, or near the drive enclosure. This includes
equipment drawings and manuals.
• Never use fork trucks to lift cabinets that are not equipped with lifting tubes. Be sure
that the fork truck tines fit the lifting tubes properly and are the appropriate length.
ESD Sensitive Equipment!
• Always be aware of electrostatic discharge (ESD) when working near or touching components inside
the cabinet. The printed circuit boards contain components that are sensitive to static electricity. Handling and servicing of components that are sensitive to ESD should be done only by qualified personnel and only after reading and understanding proper ESD techniques. The following ESD guidelines
should be followed. Following these rules can greatly reduce the possibility of ESD damage to PC
board components.
• Always transport static sensitive equipment in antistatic bags.
• Always use a soldering iron that has a grounded tip. Also, use either a metallic vacuum-style plunger
or copper braid when desoldering.
• Make certain that anyone handling printed circuit boards is wearing a properly grounded static strap.
The wrist strap should be connected to ground through a 1 megohm resistor. Grounding kits are available commercially through most electronic wholesalers.
• Static charge buildup can be removed from a conductive object by touching the object to a properly
grounded piece of metal.
• When handling a PC board, always hold the card by its edges.
• Do not slide printed circuit boards across any surface (e.g., a table or work bench). If possible, perform PCB maintenance at a workstation that has a conductive covering that is grounded through a 1
megohm resistor. If a conductive tabletop cover is unavailable, a clean steel or aluminum tabletop is
an excellent substitute.
• Avoid plastic, Styrofoam™, vinyl and other non-conductive materials. They are excellent static generators and do not give up their charge easily.
• When returning components to Siemens LD A, always use static-safe packing. This limits any further
component damage due to ESD.
NXG ToolSuite Software User Manual About This Manual
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Separation of Manuals
This manual is one component of a series of manuals intended for use with the NXG ToolSuite Software Package.
Each part in this series is for use by individuals having unique job functions and qualifications. The manuals in this
series are listed below:
• NXG ToolSuite Software User Manual (902291)
• NXG Communications Manual (902399)
• NXG Control Manual (19001588)
The NXG ToolSuite Software User Manual (902291) provides a detailed description of ToolSuite, a PC-based
application that integrates various software tools used for NXG based Drives. The NXG ToolSuite is a high-level
GUI that runs on a PC that is equipped with the Microsoft Windows operating system. The NXG control and the PC
running the NXG ToolSuite interface with each other using Ethernet and TCP/IP protocol.
The NXG Communications Manual (902399) describes the NXG control communication board, which enables
network communication via a variety of protocols and enables modem connection.
The NXG Control Manual (19001588) describes the NXG control system. The Harmony family of drives is a
collection of MV drives with different power topologies and cooling methods. The unifying factor with the drives is
the NXG control system - a second generation control for the Harmony line.
All manuals contain a readers’ comments form. Please complete these forms and return them to us. Monitoring your
feedback allows us to continue to exceed your expectations and provide complete, effective, easy-to-use product
documentation.
Reference Tools
Many steps have been taken to promote the use of this manual as a reference tool. Reference tools include the
following:
• A thorough table of contents for locating particular sections or subsections
• Chapter number thumb nails in the outer margins for easy location of chapters
• Special text styles are applied to easily differentiate between chapters, sections, subsections, regular text,
parameter names, software flags and variables, and test points
• A comprehensive index
If you have any comments or suggestions to improve the organization or increase the usability of this manual, please
complete the Readers’ Comments Form located at the end of this manual and return it to Siemens LD A Document
Control.
About This Manual
About This Manual NXG ToolSuite Software User Manual
viii 902291: Version 3.0
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The following conventions are used throughout this manual:
• The terms “Perfect Harmony,” “VFD,” “variable frequency drive,” and “drive” are used interchangeably
throughout this manual.
• Chapter numbers are highlighted in the outer margins to facilitate referencing (see margin).
• Test points and terminal block designations are shown in uppercase, boldface (e.g., TB1A).
∇ ∇ ∇
* Note: Hand icons in the left margin alert readers to important operational or application information that
may have special significance. The associated text is enclosed in a border for high visibility.
Attention! Attention icons in the left margin alert readers to important safety and operational
precautions. These notes warn readers of potential problems that could cause equipment damage or
personal injury. The associated text is enclosed in a border for high visibility.
Caution - Electrical Hazard! Electrical hazard icons in the outer margins alert readers to important
safety and operational precautions. These notes warn readers of dangerous voltages, potential safety
hazards, or shock risks that could be life threatening. The associated text is enclosed in a border for high
visibility.
ESD Warning! These icons in the left margin alert readers to static sensitive devices. Proper
electrostatic discharge precautions should be taken before proceeding or handling the equipment.
NXG ToolSuite Software User Manual NXG ToolSuite Overview
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1.1 Overview
The NXG ToolSuite is a PC-based application that integrates various software tools used for NXG based drives. With
the ToolSuite, you can navigate through a drive’s features using a PC and a mouse or touch screen, allowing you to
monitor and control that drive’s functions quickly and easily. This makes the ToolSuite more convenient to use than
a keypad. The NXG ToolSuite is a high-level GUI that runs on a PC equipped with the Microsoft Windows operating
system. The NXG Control and the PC running the NXG ToolSuite interface with each other using Ethernet and TCP/
IP protocol.
The ToolSuite contains the following tools:
• Drive Tool – Chapter 2
• Debug Tool – Chapter 3
• SOP Utilities – Chapter 4
• Configuration Update Utility – Chapter 5
CHAPTER
1 NXG ToolSuite Overview
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Insert the Siemens NXG ToolSuite CD into your PC’s CD drive. Open Windows Explorer and select the CD Drive.
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s 1 Double Click on the file ToolSuite Setup vx.x.exe (vx.x will vary based on the latest software version).
The “ToolSuite Installation Wizard” dialog boxes should appear as shown above. Follow the instruction and select
the “Next>” button.
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This dialog box shows the version information for all of the ToolSuite software components. Select the “Next>”
button.
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Select the “Next” button to begin the installation.
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If the installation was successful, the following dialog box will appear. Click “Finish”.
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s 1 1.2 Starting ToolSuite
The ToolSuite installation program will place an icon on your PC’s desktop like the one shown below. Double click
the icon to start the ToolSuite.
Once the ToolSuite is started, the following dialog box should appear:
At this point, you can invoke one of the Tools listed below:
Drive Tool – Chapter 2
Debug Tool – Chapter 3
SOP Utilities – Chapter 4
Configuration Update Utility – Chapter 5
∇ ∇ ∇
Siemens - Tool Suite.lnk
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The NXG Drive Tool is the main graphical interface to the Drive. Its purpose is to manage all of the drive features
and provide the user with a user-friendly view of the drive. The main features of the NXG Drive Tool are:
• Drive Configuration
• Drive Variable Graphing
• Drive Status
• Drive Control
2.1 Drive Configuration Features
• Folders for each drive configuration category (matches the keypad Quick Keys)
• Icon colors:
o If multiple configuration files option is NOT enabled then:
GREEN = default
RED = changed from default
o If multiple configuration files option IS enabled then:
GREEN = master config file parameter and default
RED = master config file parameter changed from default
LIGHT BLUE = secondary config file parameter and default
DARK BLUE = secondary config file parameter changed from default
• On screen help and ID identifier (matches the keypad IDs for Speed Menus)
• All parameters editing assisted by min, max limits, and defaults
2.2 Drive Variable Graphing Features
• Adjustable Time Scale
• Pick List Selectable Variables
• Graphing Capability Of Up To 10 Variables
• Individual Variable Offsets
• Individual Variable Scaling
• Customizable Graphics
• Fonts, Color, Styles
• Freeze Graphics
• Freeze Graph On Fault
CHAPTER
2 NXG Drive Tool
• Freeze On Settable Trigger
• Zoom Graph
• Printable Graphics
• Exportable Graphics
o Meta
o BMP
o Text
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2.3 Drive Status Features
• 7 Programmable Display Variables
• Pick List Selectable Variables
• First 4 Synchronized to Keypad
• Fault and Alarm Indicators (Traffic Lights Red = Fault, Yellow = Alarm, Display Flashes)
2.4 Drive Control Features
• Manual Start Button
• Stop Button
• Fault Reset Button
• Show Fault/Alarm Log Button
2.4.1 Drive Tool Pull Down Menu Features
File:
• Load configuration files
• Reset to Factory Defaults
• Create config file
• Save Data
• Save Data As
• Display active config file
• Drive Parameter Data
o Print Data
o Write Data to Text File
• Set Factory Defaults
• Options
• Enter manual speed: Ctrl+D
• System Program
o Download New System Program
o Display System Program Name
o Upload System Program
• Network
o Make Network 2 same as Network 1
o View Network Module Types
View:
• Configuration Window
• Graphics Window
• Status Window
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Security:
• Enter Security Code: Ctrl+S
• Security Edit
• Change Security Code
• Security Level Clear
Status:
• Elapsed Time
o Preset
o Reset
o Display
• Input kW Hours Consumed
o Preset
o Reset
o Display
• Output kW Hours Consumed
o Preset
o Reset
o Display
• Cells
o Display Cell Status
o Display Bypass Status
o Reset Bypassed Cells
• Set Clock Time
Logs:
• Fault Log
o Display Log
o Clear Log
o Store Log in File
o Print Log
• Historical Log
o Display Log
o Store Log in File
o Print Log
• Event Log
o Display Log
o Store Log in File
o Print Log
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Diagnostics:
• Speed Test
o Start Speed Test
o Stop Speed Test
Calibration:
• Auto-Tune
2.5 Starting and Configuring the Drive Tool
If no configured Drives exist, it will be necessary to configure a new one. To do this, click the “New” button in the
“Drive Configurator” area of the ToolSuite dialog box shown below.
In the new dialog box shown below, select the “Use Default Values” Operation Type. Select “Harmony” from the
Type Selection drop-down list and enter a drive name in the space provided. Click the “OK” button.
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The ToolSuite dialog box will reappear, now showing the newly configured drive “New Drive.” Refer to the Ethernet
Setup section for PC-to-drive communications setup information.
2.6 Setting Up Ethernet (TCP/IP) Communications
Go to each drive and use that drive’s keypad to set the menu items of the “TCP/IP setup” menu (ID = 9300). The
menu items below must be updated based on the settings unique to your network:
Table 2-1: Table Network Settings
Next, set the TCP/IP address in the Drive Tool to the same value as the drive, so that it will communicate with the
drive. The following figure shows the drive’s TCP/IP address highlighted. Change this value to match that of the
drive to which you wish to communicate. Double-click the “TCP/IP server name” text or its adjacent icon to edit its
value.
Important!
To use the Drive Tool to control drives through an existing network, assign a unique IP address to
each drive.
Menu Item Menu ID Default Setting Custom Setting (Write yours here)
IP Address 9310 172.17.20.16
Subnet Mask 9320 255.255.0.0
Gateway
Mask
9330 172.17.1.1
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If the PC on which the Drive Tool runs already has the correct network settings for the LAN, the Drive Tool will start
communicating with the drive within a few seconds of the time that you make this change. Afterwards, the
Configuration window will display a tree of several folders, and the Graphics and Status windows will start
displaying data.
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2.7 Operating the Drive Tool
Now that your Drive Tool is installed and operational, please take some time to become familiar with its features, and
how to use them.
2.7.1 Fault and Alarm Displays
When a fault or an alarm condition exists, it will be annunciated by flashing the Drive Tool window (which can be
disabled via the “Configuration → Options” pull down menu), and displaying traffic lights in the lower right corner
of the window. Also, the word “Fault” will appear under Mode within the Status window. Red lights indicate Faults
and yellow lights represent Alarms, as shown below.
To display the most recent faults and alarms, click the “Show” button. A dialog box will appear, listing faults and
alarms in the order in which they occurred.
If an alarm has reset itself, the reset time will be noted. If a fault condition no longer persists, you can reset the fault
by clicking the “Reset” button in the Drive Tool window.
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If all faults have been reset, the Drive Tool window will appear as shown above, without flashing.
You can change a drive parameter by selecting the desired parameter from within the configuration window and
double clicking on it. This will cause a dialog box similar to the one below to appear. You can then type in the
desired value (some parameters will be changed from a pick list). The limits, default value, and current value are
displayed, along with a more complete parameter description than that in the Configuration Window. You can enter
a comment as a record of the change if desired. The “Set to default” button will restore the default value. The “Help”
button is not currently supported.
Parameters that are changed from the default value will appear as reddish icons within the Configuration window.
Parameters set to their default values are displayed as greenish icons.
* Note: The yellow traffic light indicates that an alarm condition still persists.
* Note: If you would like to permanently change a drive parameter, select “Configuration” →
“Save Data” from the pull down menu bar of the Drive Tool window.
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2.7.2 Graphing Display
A list of the variables that you can display in the ToolSuite is given in Table 2-2. A total of ten variables can be
displayed at the same time. Select variables with the Graphing submenu (ID# 10). Each variable has a scale factor and
an offset. The Y-axis display range is –1.0 to +1.0. All variables are required to be scaled within this range to be
visible on the screen. The value shown on the screen is the actual value divided by the chosen scale factor. Unless
otherwise indicated, the variables are in per unit; hence the default Scale Factor of 1.0 is satisfactory for most
variables.
The offset parameter shifts the zero point of the variable up or down on the plot window. For most variables, the
default offset of 0.0 is sufficient. The names of commonly displayed variables are shown in bold typeface.
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Table 2-2: List of Variables Available for Display
Variable Name Description
Ids Measured motor magnetizing current
Iqs Measured motor torque current
Ids reference Motor magnetizing current command
Iqs reference Motor torque current command
Iqs reference filtered Filtered torque current command
Flux DS Estimated motor flux
Flux QS Flux input to PLL for motor speed and flux angle estimation (typically 0.0)
Vds reference D-axis voltage command (or output of magnetizing current regulator)
Vqs reference Q-axis voltage command (or output of torque current regulator)
Output frequency Drive output frequency in rad/sec
Slip frequency Estimated motor slip frequency in rad/sec
Motor speed (frequency-slip) Estimated motor speed in rad/sec
Motor speed filtered Filtered motor speed in rad/sec
RLoss for braking Equivalent motor resistance during dual frequency braking
XLoss for braking Equivalent motor inductance during dual frequency braking
Field weakening limit Field weakening torque current limit
Dual Frequency Braking Limit Current limit during dual frequency braking
Maximum Current Limit Maximum torque limit (at output of speed regulator)
Minimum Current Limit Minimum torque limit (at output of speed regulator)
Iq gain Speed regulator enable signal
Ua reference Phase A output voltage command
Ub reference Phase B output voltage command
Uc reference Phase C output voltage command
Flux D loss filtered D-axis flux component at the loss inducing frequency
Flux Q loss filtered Q-axis flux component at the loss inducing frequency
Id loss filtered D-component of current at loss frequency
Iq loss filtered Q-component of current at loss frequency
W loss Loss inducing frequency in rad/sec
Ws filtered Filtered drive output frequency
Theta loss Flux angle of the loss inducing frequency in radians
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Flux DS filtered Filtered motor flux
Ids filtered Filtered motor magnetizing current
Iqs filtered Filtered motor torque current
Vd loss Magnitude of loss inducing voltage
Ids no load No-load motor current
Stator resistance Stator resistance
Wp reference Pulsation frequency in rad/sec
Output vector angle Motor flux angle in radians
Volt second phase A measurements Measured phase A motor volt-seconds
Volt second phase B measurements Measured phase B motor volt-seconds
Volt second phase C measurements Measured phase C motor volt-seconds
Ia current measurements Measured phase A motor current
Ib current measurements Measured phase B motor current
Ic current measurements Measured phase C motor current
Ids measured current after synch
filter (V/Hz)
Not used
Iqs measured current after synch filter (V/Hz)
Not used
Raw speed demand *
Raw speed demand in rad/sec
Auxiliary demand before ramp *
Auxiliary demand before speed ramp in rad/sec
Auxiliary demand after ramp *
Auxiliary demand after speed ramp in rad/sec
Speed demand *
Speed demand before speed ramp in rad/sec
Speed profile output *
Output of speed profile routine in rad/sec
Critical speed avoidance output *Critical speed avoidance output in rad/sec
Polarity change output *Output of polarity change function in rad/sec
Minimum demand output *
Output of minimum limit routine in rad/sec
Ramp output *
Output of speed ramp function in rad/sec
Speed demand at limit input *
Input signal to speed (maximum) limit function in rad/sec
Speed reference *Motor speed reference in rad/sec
Raw flux demand Flux demand from menu
Variable Name Description
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Flux ramp output Output of flux ramp controller
Energy saver output Output of energy saver controller
Field weakening output Output of field weakening controller
Flux reference Flux reference
Id input current Real component of input current
Iq input current Reactive component of input current
Phase A input current Phase A input current
Phase B input current Phase B input current
Phase C input current Phase C input current
Phase A input voltage Phase A input voltage
Phase B input voltage Phase B input voltage
Phase C input voltage Phase C input voltage
Zero sequence average RMS value of zero sequence component in input voltage
Negative sequence D voltage D-component of negative sequence in input voltage
Negative sequence Q voltage Q-component of negative sequence in input voltage
D voltage Amplitude of voltage of line voltage (taking transformer tap setting into
account)
Q voltage Q-axis component voltage used to drive input PLL for frequency
estimation.
Input frequency Input (line frequency) in rad/sec
Input power average (kilowatts) Input power
Input power factor Input side power factor
Ah harmonic coefficient Amplitude of A-component of harmonic chosen using menu setting
Bh harmonic coefficient Amplitude of B-component of harmonic chosen using menu setting
Transformer thermal level Output torque limit set by transformer thermal limit regulator
One cycle reactive current level Output torque limit set by transformer thermal limit regulator
Single phasing current level Output torque limit set by input single-phasing regulator
Under Voltage level Output torque limit set by input undervoltage regulator
Input side flux Input voltage converter to flux for Up Transfer
Line Flux Vector Angle Angle of input voltage in radians
Output Neutral Voltage Input side neutral voltage
Variable Name Description
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Refer to the Command Generator Diagram, DWG 459713, to see where these variables are used in the control code.
2.7.3 Time Scale Adjustment
The total time span of the screen can be adjusted using the Time Scale parameter (ID # 10000). The update rate of the
screen depends on the traffic on the network. A small time scale of 20 seconds or less may result in broken traces. A
time span of 30 seconds results in a uniform display with no gaps in the traces.
2.7.4 Freezing Graph on Fault
The screen can be set to automatically “freeze” whenever a fault occurs. This feature is enabled/disabled by clicking
the right mouse button while the cursor is on the graphing window and selecting “Freeze On fault.” The “Freeze on
trigger” function must be disabled to enable the “Freeze On fault” menu selection. When this feature is enabled, the
“Freeze On fault” menu selection will display a check mark and the Graphics window title will show “Graphics –
Freeze On Fault”. When this feature is enabled and all faults are cleared and a subsequent fault occurs, the graph will
freeze five samples after the occurrence of the fault. There are 100 samples across the entire graphing time scale.
Sync Motor Field Current Field current command (for synchronous motor)
Encoder Speed Encoder speed output
Motor Voltage Motor voltage (or drive output voltage)
Output Power Average (kilowatts) Output Power
Phase A filter current Filter current in A phase
Phase B filter current Filter current in B phase
Phase C filter current Filter current in C phase
Measured Phase A Volts Actual Drive voltage A phase
Measured Phase B Volts Actual Drive voltage B phase
Measured Phase C Volts Actual Drive voltage C phase
Measured Output Neutral Voltage Drive neutral voltage
Max Available Output Volts Max available output voltage
Input Reactive Power (KVAR) Input KVAR
Drive Efficiency Efficiency
Drive State Drive state
Up Transfer State Up transfer state variable
Down Transfer State Down transfer state variable
Drive Internal Losses Difference between output and input power
Excess Input Reactive Current Input reactive current over max allowed
Speed Droop Speed Droop in rad/sec
Variable Name Description
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2.7.5 Freezing Graph on Trigger
The screen can be set to automatically ‘freeze’ whenever the value of a variable being graphed reaches a set trigger
point condition. This feature is enabled/disabled by clicking the right mouse button while the cursor is on the
graphing window and selecting “Freeze on trigger.” The “Freeze On fault” function must be disabled and the trigger
must be properly set-up to enable the “Freeze on trigger” menu selection.
The trigger is set-up by clicking the right mouse button while the cursor is on the graphing window and “Set up
trigger…” is selected. The variable on which the trigger will be based must be selected, as well as the type of trigger
and the trigger point. The trigger point is based on the non-scaled non-offset variable value. The number of samples
which will be displayed after the trigger point is reached must also be entered. There are 100 samples across the entire
graphing time scale.
When this feature is enabled, the “Freeze on trigger” menu selection will display a check mark, and the Graphics
window title will show “Graphics – Trigger enabled.” When this feature is enabled and the trigger conditions are
satisfied, the graph will freeze after the number samples entered in the trigger set-up are subsequently graphed. The
Graphics window title will then show “Graphics – Graph triggered.”
2.7.6 Post Processing of Data
The screen can be manually “frozen” by placing the mouse over the plot window, clicking on the right mouse button
and choosing the “Freeze/Unfreeze” command (or using CONTROL P on the keyboard), or by using either of the two
automatic methods described above. While the screen is frozen, the “Export” command (available using the right
mouse button) can be used to save the plot as a Windows MetaFile, BitMap File, or in a tabular form in a Text File
(that can be read by Excel or any Text Editor). Alternatively, the plot can be sent directly to a printer.
∇ ∇ ∇
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The NXG Debug Tool is PC-based application software that provides a remote graphical user interface for Siemens
medium voltage Perfect Harmony NXG series drives. With the Debug Tool, you can examine drive variables using a
PC and a mouse, allowing you to monitor that drive’s functions quickly and easily. The NXG Debug Tool is a highlevel GUI that runs on a PC equipped with the Microsoft Windows operating system. The NXG Drive Control and
the PC running the NXG Debug Tool interface with each other using Ethernet and TCP/IP protocols.
3.1 System Requirements
The NXG Debug Tool is a Microsoft Windows application requiring the .NET 2.x Framework. It requires Windows
98/NT4.0/2000/XP, at least 128 MB of RAM, and a minimum of 15 MB of disk space.
3.2 Starting and Configuring the Debug Tool
If no configured drives exist, it will be necessary to configure a new one. To do this, click the “New” button in the
“Drive configurator” area of the ToolSuite dialog box shown below.
In the new dialog box shown below, enter a drive name and the IP address of the drive in the space provided. Click
the “OK” button.
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The ToolSuite dialog box will reappear, now showing the newly configured drive “New Drive.”
Double click the icon “New Drive” to start the Debug Tool. If the IP address is correct, the display should appear as
shown below:
3.3 Operating the Debug Tool
The debug tool was designed to replace the local debug monitor and keyboard interface hardware previously used to
provide internal debug information about the NXG control. The tool uses pull down menus and contains the same
screens as the previous debug monitor interface. To gain access to a feature of interest, simply click on the pull down
menu to select that feature. Below is a list of available features:
Operation:
• Change IP Address
• Exit
Status:
• General
• Advanced
• Modulator
• Power Cell Status 1
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• Power Cell Status 2
• AFE Status
• Wago Status
• Internal I/O 1
• Internal I/O 2
• Parallel Data 1
• Parallel Data 2
SOP:
• Command Generator Flags
• Comparators
• Counters
• Drive Misc Status Flags 1
• Drive Misc Status Flags 2
• Loss of Signal Flags
• Serial Flags
• Static Flags
• Synch Transfer Flags
• Temp Flags
• User Interface
• Active Variables/Counters/Timers
• Timers
o Menu Based
o SOP Based
• Wago
o Digital Inputs
o Inputs 1-8
o Inputs 9-12
• Digital Outputs
Faults/Alarms:
• Drive
o Word 1 bits 0-31
o Word 1 bits 32-63
o Word 2 bits 0-31
o Word 2 bits 32-63
o Word 4 bits 0-31
o Word 4 bits 32-63
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• User
o Bits 0–31
o Bits 32-63
Networks:
• Status
• Network 1
o Input Flags
o Output Flags
o Fixed Registers
o Register Data
o Global Data
• Network 2
o Input Flags
o Output Flags
o Fixed Registers
o Register Data
o Global Data
• Internal Net
• TCPIP Net
• Hex
Files:
• List
o Config Files
o SOP Source Files
o SOP Hex Files
• Upload
o Config Files
o Drctry File
o Event Log File
• SOP Source Files
• SOP Hex Files
• System Files
o Language File
o MinMax File
o Modulator Look-up table file
o Version History File
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Logs:
• Fault
• Historical
• Event Log File
About:
• Current NXG Debug Tool version and connected NXG Drive Software version
∇ ∇ ∇
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4.1 Introduction
Siemens ID Series of digital drives contain customized programmable logic functions that define many features and
capabilities of the drives. These logic functions are combined into a system program that can be edited either at the
factory or in the field. Examples of logic functions include start/stop control logic, input and output control logic
(e.g., annunciators, interlocks, etc.), drive-to-machinery coordination, and more. The system program is stored on the
system non-volatile memory, and runs in the drive under an interpreter, causing the intended logic statements to
perform their functionality.
The system program is the logic that maps the external I/O into the functionality of the drive. In its simplest form, it
just maps internal states to external points. In more complex forms, additional complex logic, in the form of Boolean
logic, as well as timers, counters, and comparators, express the system functionality to the drive.
Generally, this type of logic takes the form of ladder logic diagrams. Sum-Of-Products notation is a shorthand
method for expressing the ladder logic in textual form. In fact, there is a direct correlation between the two, which is
covered in the section on ladder logic and Boolean theory.
The SOP Utilities is a group of utilities under the ToolSuite umbrella program. It is launched much the same as the
other tools. It performs most of the functionality on the PC running the ToolSuite, but has serial communications
capability for uploading and downloading the system program directly to the drive via an RS232 interface between
the drive and the PC.
The purpose of the SOP Utilities Tool is to convert logic statements in the form of Sum-Of-Products (SOP) notation
into a form of machine-recognizable code that is run under the built-in drive SOP interpreter. The mechanics of this
operation are described in the drive manual and are not discussed in this context.
4.2 SOP Utility Tool Overview
To understand the use of this utility, we must look at the individual functions and describe the purpose of each. These
functions are summarized in Table 4-1.
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Table 4-1: SOP Utility Terminology
Name Function
Source File The source file is an ASCII text file containing simple Boolean statements and operators.
This file is edited on a PC using any standard ASCII text editor. This file is used as the input
to the compiler program and is unreadable by the drive. The source file uses the .SOP file
extension.
Hex File The hex file is a compiled version of the source file, and is in the format of an Intel ASCII
Hex downloadable file. The hex file is a result or output of the compile process. This is the
file that is sent from the PC to the drive over the communications cable, using the serial
communications function of the Tool and software functions chosen from the drive menus.
The hex file is viewable by a text editor, but is unreadable by the user. It must be reverse
compiled to be viewed by the user. Optionally, during the compile process, the entire source
file, with comments, may be appended to the hex file.
ASCII Text
Editor
The ASCII text editor is a software program used to edit the source file of the system
program. The default is Windows Notepad, but any text editor can be used, as long as no
hidden, unprintable characters are used.
Compiler
Function
The compiler function is built into and invoked from the SOP Tool. It is used to translate the
ASCII text source file (.SOP) into hex. This program reads the input source file (.SOP),
validates the statements for proper syntax and symbolic content, generates primitive logic
functions that implement the higher level logic statements, and stores this information into an
output file using Intel hex file format. The resulting .HEX file can be downloaded to the
drive. With Version 2.4 NXG drive software, the source file can be appended to the hex file
for retrieval by the reverse compiler function.
Reverse Compiler
Function
The reverse compiler program does the opposite of the compiler program. It uses the
compiled hex file (with a .HEX extension) as the input, and produces an ASCII text output
file (with a .DIS [for disassembly] extension) that can be read by the user via any standard
text editor software. This program is useful if the original source file is lost, damaged, or
unavailable. Note that any comments in the original source file will not be reverse compiled,
since they are ignored by the compiler program when the hex file is created with Version 2.4
NXG drive software. If the source file is appended to the hex file, a reverse compile will
retrieve the source, complete with comments, rather than go through the reverse compile
process.
Communications
Function
The communications function is used to send the compiled version of the system program
from the PC to the drive or retrieve the file from the drive. The communication options must
be configured for proper communications (i.e., baud rate, number of data bits, number of stop
bits, and parity settings).
Communications
Cable
This is a serial communications cable over which data (e.g., the system program) is
transmitted between the drive and the PC. The exact specifications of this cable vary, based
on the drive being used and the type of connector available on the serial communications port
of the PC.
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Product Type The supported product type is generally a Siemens ID-Series motor drive, Perfect Harmony,
or other compatible drive. It uses the system program that is stored in a nonvolatile portion of
memory on the drive to evaluate logic statements in order to perform their functionality with
the drive operation or I/O. Within its menu structure, the drive contains software functions
used to enable uploading and downloading between the drive and the PC via RS232 serial
communications. The settings of communications parameters in the drive must match the
settings in the communication options in the Tool for proper communications during system
program transfers.
*
Note: Intel hex format is an ASCII representation of binary data. The hex file mentioned in the previous
table uses various record types to set the download location and to detect errors. The source file, if
included, is simply appended to the end of the Intel Hex file, and does not affect the operation of the
SOP file. It is not loaded into memory, but simply stored for future reference or retrieval.
Name Function
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4.3 Starting the SOP Utility Tool
Start the SOP Utility Tool by selecting the Utilities Tab as shown in Figure 4-1.
Figure 4-1: SOP Utility Start Window
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Once the SOP Utility Tool starts, the opening screen, shown in Figure 4-2, will display.
Figure 4-2: SOP Utilities Opening Screen
Selecting the target source file also selects the target Directory (DRCTRY) file for mapping the valid Product flags
and I/O, and automatically selects the Product type (see Figure 4-3). The source file can then be further edited by
selecting the edit button. This will invoke the text editor – the default being the Windows Notepad. The default editor
can be changed by selecting the “Change Default Editor” and then browsing to the desired text editor. A word
processor can be used, but only if the output file is set for pure ASCII text, with no formatting characters embedded in
the saved file.
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Figure 4-3: SOP Utilities Window
4.4 SOP Development Process
The SOP general process consists of:
• Creating a text document explaining, in prose, the operation of the system, including all fault handling
processes.
• Creating a ladder logic diagram of the control logic that is to be implemented in the SOP, including a detail
of the I/O interface as matches the system drawings.
• Converting the ladder logic into sum-of-products statements utilizing Boolean logic and DeMorgan’s
Theorems.
• Creating a text document, the source file, with the appropriate statements and detailed comments as to the
system use of the logic. This text file is given the extension of .sop, for sum-of-products notation source file.
The textual description is created in the SOP text templates. The templates are a series of spreadsheets that textually
define the standardized TB2 designation, the WAGO assignment, the sequence of operation, etc. Templates are
available for both air-cooled and water-cooled systems.
The standard logic diagrams and accompanying SOP function blocks are defined in Engineering Reports and are
useful for creating the standardized functions of the SOP – both in ladder logic and in sum-of-products notation. The
Engineering Report provides a standard means to produce customer SOPs. The function blocks can be used as
presented, or can serve as a template for customer requests not specifically addressed by the blocks.
The SOP input source file is composed in an ASCII text editor and compiled by a Siemens LD A compiler. SOP
testing is performed at the Siemens LD A facility.
The remainder of this chapter details the process of creating and compiling the SOP.
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4.5 Overview of the Compile Process
Once the source file is completed, the next stage is compilation. This is necessary to transform a human-readable
document into a machine-readable program.
Compilation requires a directory file, which is determined by the type of target drive to be used. This is determined in
one of two ways. Either the drive type is embedded as the first line of the source file, or if this statement is missing,
the drive type must be explicitly determined by selecting from a picklist.
The directory file contains data critical to the compile process. It is an ASCII text file, which contains the variable
names along with designators that the compiler uses. Comments are included to help understand the meaning and use
of the variables. It is useful to view the directory file as the system program is being developed, to obtain the correct
spelling of the system flags and variables. It is for this reason that the file is readable text. However, it is critical to
not edit the directory file without first-hand intimate knowledge of the data structures used within the file.
The compilation process reads each logic statement from left to right, creating data tables for the variables used, logic
statements, operators, and output assignments. The result is readable by a special interpreter that resides within the
product core code. The actual names are not used, but are substituted by the compile process, substituting and
assigning special internal memory locations for each. This reinforces the need for proper spelling of variables as they
appear in the directory file.
Selecting the Compile button begins the compile process, which then prompts the user to select whether to attach the
source file to the generated hex file:
On successful completion of compilation, a dialog box will pop up stating this along with additional pertinent
information on the size of the file, checksum of the SOP hex file, and number of counters and timers used, along with
other information that is useful for debugging purposes by factory personnel:
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Should an error occur during compilation, an error dialog will appear:
Acknowledging the error reveals the source of the error by logic statement number, and by text file line number:
An output file is not generated until a successful compilation occurs. Should the name of the source file not conform
to the 8.3 DOS naming convention, and the Product type be a NextGen drive, an additional message will appear:
For a list of other compile errors, see Table 4-6 in this chapter.
* Note: This is not a limitation of the SOP compiler, but of the NXG operating system file system, so it
only applies to this Product type.
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4.6 Input Source File
The input source file is the ASCII text version of the system program that is edited by the user. Editing can be
performed using any standard ASCII text editor on a PC. The file can contain both logic statements and explanatory
comments to aid in documenting the content and intent of the logic statements. With the exception of simple true and
false logic assignments, the order of the statements in the source file is the order in which the statements will be
executed by the drive’s run time software. True and false statements are placed first in the hex file at the time of
compilation, and are executed only once after system program initialization. All other statements are executed in
order from top to bottom in a continuous manner. Results of the evaluation of a logic statement are immediately
available as inputs to statements that follow.
The format for a system program source statement is as follows:
output_symbol = {unary_operator} input_symbol { [ binary_operator {unary_operator} input_symbol ] ... };
where:
output_symbol represents an output symbol defined in the symbol directory file
= the assignment operator (only one per source statement)
input_symbol represents an input symbol defined in the symbol directory file
unary_operator Boolean NOT operator (/ character)
binary_operator Boolean operators OR and AND (+ and *, respectively)
{ } represents optional syntax
[ ] represents required syntax
... the previous operation may be repeated
; statement terminator
The statement can span multiple lines and can contain spaces as needed for readability. The output_symbol is a
required field and can be any symbol that would be valid as an output variable. The output_symbol is followed by one
or more optional spaces and then the required assignment operator “=”. A source statement can contain only a single
assignment operator.
The input side of the equation must equate a simple Boolean form (either true or false) after evaluation. It is formed
from either a simple input symbol (possibly negated with a NOT unary operator) or a combination of input symbols
on which binary operators operate. Input symbols and binary operators are evaluated left to right by the run time
software. The precedence of operations is summarized in the next section.
The execution flow of the run time software is as follows:
1. Comparator evaluations are performed and the resulting system flags are updated.
2. Input flags are scanned and their present state(s) are recorded.
3. Logic equations are executed based on the recorded input states.
4. The results of the logic statement(s) are output.
* Note: Program statements may span multiple lines by breaking the line at a convenient operator. The
single line length of 132 characters should not be exceeded.
*
Notes:
• Each statement must be terminated with a semicolon.
• Symbol names are not case-sensitive to the compiler. The symbols symbol_1, Symbol_1, and
SYMBOL_1 are all treated identically.
* Note: In the case of logic assignments, where the source state is a simple “true” or “false,” the
assignment is made only once at runtime software initiation.
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A sample input source file is illustrated at the end of this chapter. Although this sample source file may appear to be very
complex, it contains only four basic types of statements:
• Logic statements that can continue to additional lines
• Comment lines for explanation of code operation and purpose, or to document I/O assignments
• Text labels for user-designated faults
• Assignments that substitute a user-defined label for an internal variable for easier understanding
Semi-colons serve a dual purpose in the source file. Every logic statement must be terminated by a semi-colon. Also,
comments are any text that follows the semi-colon at any placement location on a line. All lines that begin with text
instead of a semi-colon are interpreted by the compiler program as logic statement lines. Program source lines may
continue to other lines and are finally terminated with a semi-colon. This technique can be used to make the logic
more readable. Based on this, comments may not be added within the scope of a single, multi-line program statement,
as the semi-colon will be interpreted as the end of the logic statement, and the next line without a semi-colon, as the
next logic statement.
Logic operators separate variables used within logic statements. Every variable must have some logic operator
following it in the logic statement. The logic operators supported in the SOP are the AND (*), OR (+),
ASSIGNMENT (=), statement termination (;), and NOT (/).
Comment lines provide additional information to the reader, but provide no additional information for the compiler. It
is strictly a tool for better understanding of the intended logic of the logic statements. As such, comments should not
be added simply to be there, but must be structured to provide an overview of what the logic is trying to accomplish
in the system. This information is vital to the maintenance of the SOP for future reference as to the intent of the logic,
not only for the originator, but also for anyone who must maintain or change the code in the future. It is a tool for
conveying information that is not intuitively apparent in the logic statements themselves.
Substitution names also serve to clarify the intent of the logic statements. When a generic system flag, such as a
timer, counter, I/O assignment, or temp flag, is used for a specific purpose, consider using the substitution operator to
define a label that better suits its functionality. For example, if an output is used to switch on a pump or fan, then
consider renaming the output “Pump_on”, or “Fan_on” instead of the generic “ExternalDigitalOutputxxx_O”.
*
Notes:
• All source code comment lines are ignored by the system program compiler. Only the program
statements (with any optional comment suffixes omitted) are compiled into the binary (hex formatted) system program that is downloaded to the drive. For this reason, the process of reverse compiling the system program yields source code without comments. For more information on the process
of reverse compilation, refer to Table 4-1 and Table 4-7.
• Comment text cannot be added within the context of a multi-line logic statement, but must follow
the semi-colon terminating the logic statement. Logic statements can extend to multiple lines for
readability, but must be terminated by a semi-colon at the end of the statement.
• Logic statements must not exceed 132 characters in length. The compiler truncates any single line
beyond that length and ignores anything further in the line. This length limitation is for a single line,
and the count is reset when a new line is started. Therefore, continuing long logic statements to multiple lines is essential for proper compilation as well as better readability.
• Typically, logic statements are broken at the OR operator (+) in the sum-of-products notation.
• All statements must be in the form of sum-of-products notation.
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4.6.1 System Type Identification
Because the compiler and reverse compiler support a number of different end products, the compiler needs to know
what the target system is, so that it can generate the proper code for that target system.
To identify the system type, include the system type identifier command as the first line in the system program SOP file.
The syntax of this command is shown below:
#system_type
The statement must be on the first line, a pound sign (#) character must appear in column 1, and the program line
must end with a semicolon. For Perfect Harmony drives, the proper format of this command is shown below:
#NEXTGEN;
The compiler also recognizes other system types.
Table 4-2 shows the interface for the pull-down product type selector. Alternatively, if you have an SOP file that does
not include the #system_type; identifier, then the Product Type selector pull-down is activated and a selection must
be made before a directory file can be selected or before compilation is enabled (note that the Compile button is grayed
out until after the selection is made).
* Note: A comment can follow the semicolon with the system type identification command.
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Table 4-2: Product Types Recognized by the System Compiler
Figure 4-4: SOP Utilities Compiler Showing Product Type Pull-Down
Target Product Type Identification Command
Perfect Harmony #HARMONY;
454 GT #ID_454GT;
ID-CSI #ID_CSI;
DC Harmony #HARMONY_DC;
ID-2010 #ID_2010;
NXG Control #NEXTGEN
Silcovert H #SILCOVERT_H
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Table 4-3: Directory Filename Associations
4.6.2 SOP Source File
The SOP file, as mentioned previously, is written with a text editor or a word processor set for pure ASCII text (having a
.TXT file extension) with no control or formatting codes, with the exception of horizontal tabs (ASCII code 09h) and
carriage returns (0Dh). Only printable characters and spaces (20h) can be used. The file consists of the format shown
in Table 4-4.
Target System Type Directory File Name
Perfect Harmony DRCTRY.PWM
454 G T DRCTRY.IGB
ID-CSI DRCTRY.CSI
DC Harmony (e.g., torch supply) DRCTRY.HDC
ID-2010 DRCTRY.DC
NXG Control DRCTRY.NXG
Silcovert H DRCTRY.SIH
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Table 4-4: SOP Text File Format
Item Description
Drive type
specifier
This must reside on the first line of the file prefixed with the pound sign (#) and followed with
the name of the drive (in the case of Perfect Harmony this would be #NEXTGEN;).
Header
A comment field containing the following information:
Title - Siemens LD A Perfect Harmony drive
Program part number
Customer name
Sales order number and Siemens drive part number
Drive description
Original SOP date
File name
Engineer name (Originator)
Revision history (date and change description).
Example:
; Siemens Perfect Harmony Step Pwm Ac Motor Drive
; System Operating Program - Standard Performance
; NXG Control
;
; Program Number: 18xxxxxx.SOP
; Customer: xxxxxxxxxxxxxxxxxxxxxx
; Siemens Sales Order: xxxxxxx
; Siemens Part Number: xxxxxx.xx
; Description: xxxxx HP, xx.x kVac in - x.x kVac out, Size xx
;
; Original mm-dd-yy
;
; REVISIONS:
; Changed mm-dd-yy -
Operators Comment field containing operators and symbols
Example:
; = equals * logical AND + logical OR / logical NOT
; ; comment line
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I/O specifier
Comment field describing the system input and output flags as they relate to the external system.
This would include any user faults and notes on menu settings, such as Comparator setups and
XCL settings, as they apply to the system program (more on this later). These can (and should) be
grouped logically to allow easy access to information and to make the SOP more understandable.
Example:
;--------------------------------
; Wago Digital Inputs (dedicated)
;--------------------------------
; RemoteStart_I EDi01-a - Remote start - Momentary close to start
; RemoteStop_I EDi01-b - Remote stop - Momentary open to stop
; RemoteFaultReset_I EDi01-c - Remote fault reset - Momentary close to reset drive faults
;-----------------
; Comparator Flags
;-----------------
; Values of “Fixed Percentage” is what is entered in the comparator menu.
; The percentage is entered as the desired percentage of signal full scale.
; Comparator1_I Coolant conductivity > 3 uS Process Alarm
; 1A - Analog input 3
; 1B - Fixed percentage = 30 %
; 1C - Magnitude comparison
User fault
messages
Assigns the text to be displayed when this particular user fault is activated.
Example:
; UserText1 = “UPS On Inverter”;
; UserText2 = “UPS Alarm”;
Replacement
variable
assignment
Allows the user to redefine the label on common variables to make the SOP code easier to read.
The compiler only uses this during compile. If any information is to be stored, it is recommended
that the source file be attached.
Example:
$ManualControlOn = Counter01;
$ManualControlOff = CounterReset01;
Main logic
section
All the equations and assignments for the configuration, annunciation, and operation of the drive.
These should be logically arranged with careful consideration given to the order of evaluation of
the equations.
Item Description
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4.6.3 Input Flags
Input flags are identified by variable_I. Input flags are symbols that are encountered on the right-hand side of a source
statement (to the right of the equals sign) that express the state of an input to the system. They may reflect the state of a
digital input (e.g., ExternalDigitalInput01a_O, ExternalDigitalInput01b_O) or switch (e.g., KeypadManualStart_O),
the state of a system process (e.g., Cells_I, OverloadFault_I, OutputPhaseOpen_I), internal variable, Comparator flag
(e.g., Comparator_1), or a simple literal (TRUE, FALSE). These input flags are combined using the unary and binary
operators to form logic expressions.
Digital input flags generally represent the state of a discrete digital input signal into the system. These may be a 24-
volt logic input, a key switch or push-button in the system, or some form of a binary input. They also can be internal
flags that indicate a state or condition of the drive, e.g., faults, warnings, limits, etc. The inputs are scanned at the
beginning of each execution cycle, but may reflect older information in some cases.
System constants TRUE and FALSE are predefined and can be used as input terms to an expression.
There exists the capability to compare the value of certain system variables against preset thresholds in real time, and
then use the results of the comparisons (TRUE or FALSE) in the system program to control actions on the drive. The
variable(s) to be compared and the thresholds are entered into the system using the keypad. The output of the
comparisons (Comparator1_I ... Comparator16_I) are available for use in the system program as input symbols.
4.6.4 Output Flags
The output flags all have “_O”, tagged to the end of the variable name (variable_O). The output flags (the symbol
placed on the left-hand side of the assignment “=” operator) direct the result of the input expression towards an output
purpose. Output flags represent items such as digital outputs and system control switches.
Table 4-5: Types of Output Flags
Types Examples
digital outputs ExternalDigitalOuptput01a
system control switches AutoDisplayMode_O, RampStop_O, , RunRequest_O
* Note: Digital output flags generally represent some form of discrete digital output bit(s) from the system.
These may be a relay coil driving contacts (NO or NC), direct digital outputs, or lamp controls. The digital
output signals are updated at the completion of each system program execution loop.
*
Note: The Perfect Harmony series of drives (as well as all other ID series drives) have a set of predefined symbols that describe control outputs or “switches” that can be controlled by the system
program. These switches can control functions such as the source of the speed reference, a selection for
the system acceleration rate, and a multitude of others. In most cases, to cause the system to perform in
the intended manner, the proper control switches must be set (and others cleared) by the system program.
The default state for all control switches is FALSE. Unless the system program sets the switch to TRUE,
it will be inactive (FALSE).
* Note: No variable_I, Input variable can appear on the left side of the “=” sign. Both variable_I and
variable_O can appear on the right side of the “=” sign
* Note: Only one switch should be set at any one time from any functional grouping of switches (e.g.,
command generator input grouping).
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There is a set of Boolean temporary flags available to hold temporary or common expressions in the system program. By
using these temporary flags to hold common expressions, system program execution times can be improved. The system
program compiler does not perform any optimization, it generates code closely matching the equations as written. If
there are expressions that are repeatedly evaluated, set a temporary flag to the intermediate results, and then use the flag
instead of the longer expression.
For example:
ExternalDigitalOutput01a_O = ExternalDigitalInput01_a +
ExternalDigitalInput01_b + RunRequest_O;
SetPoint1_O = ExternalDigitalInput01_a + ExternalDigitalInput01_b +
RunRequest_O;
SetPoint2_O = ExternalDigitalInput01_a + ExternalDigitalInput01_b +
RunRequest_O ;
could be replaced with:
TempFlag01 = ExternalDigitalInput01_a + ExternalDigitalInput01_b +
RunRequest_O;
ExternalDigitalOutput01a_O = TempFlag01;
SetPoint1_O = TempFlag01; SetPoint2_O = TempFlag01;
A time-out function may be implemented with system program timers. These timers are enabled using logic
statements and the output (based on the timer expiring) is available as an input to logic statements. The time period is set
in seconds with the resolution. The unit specified in the logic statement is seconds (with a decimal fraction rounded to
the nearest internal resolution). Time intervals are up to 16,383.5 seconds for the Next Gen version of Perfect
Harmony.
The statement:
Timer01(20.0) = symbol_a;
enables timer 1 if symbol_a is true. The statement:
output_1 = Timer01;
sets the symbol output_1 true if the timer has expired (timed out). In the example above, if symbol_a is false,
output_1 will be false. If symbol_a is set true, then 20 seconds later, output_1 will be set true (assuming symbol_a
remains true).
Once the enabling logic goes FALSE, the entire time-out period must pass before the timer will time-out. Should it go
FALSE before the time-out period, the timer count is reset to zero, and the timer must go the entire period before
timing out.
Counters in a system program can be used to count the number of FALSE to TRUE transitions of the counter input. A
corresponding counter reset input is used to reset the counter value to zero. For example:
Counter01(13) = input_a;
CounterReset01 = input_b;
output_a = Counter01;
If input_b is set TRUE, Counter01 is set and held to zero. If input_b is FALSE, after 13 FALSE to TRUE transitions of
input_a, the symbol Counter01 (and output_a) will be set TRUE. After 13 transitions, Counter01 will remain TRUE
until Counter01 is cleared by CounterReset01. The maximum count value is 32767. The count value must be an integer.
4.6.5 Redefining Flag Names
To make flag names more intuitive, you can redefine flag names so that your names may be substituted for the
generic flag names thereafter. The definitions are made near the start of the program to ensure that they are defined when
needed. The format for the definitions is:
$NewFlagName=nameInDirectoryFile
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where NewFlagName is your new definition, and nameInDirectoryFile is the flag name found in the drty.ngn
file.
For example, a typical SOP program might define flags as follows:
Counter01(30) = /ExternalDigitalInput01f_I*
ExternalDigitalInpout01e_I*Timer00;
CounterReset01 = ExternalDigitalInpout01e_I;
If you include the following at the start of the program:
$FireAlarmCircuitTimer = Counter01;
$FireAlarm_I = ExternalDigitalInput01f_I;
$FireAlarmPumpHasOverheated = ExternalDigitalInput01e_I;
$FireAlarmWarningTimer = Timer00;
$ResestFireAlarmCircuitTimer01 = CounterReset01;
then the lines in the program become:
FireAlarmCircuitTimer (30) = /FireAlarm_I*/
FireAlarmPumpHasOverheated_I *FireAlarmWarningTimer;
ResetFireAlarmCircuitTimer01 = FireAlarmPumpHasOverheated_I;
4.7 Compiler Operation
As discussed earlier in this chapter, three files are accessed during the compilation process: the source (or SOP) file,
the DRCTRY.NGN (directory) file, and the output hex file. When the compiler is invoked, it first opens the SOP file
to determine if it contains a system_id definition line as the first line in the file. This line defines the target system
type to the compiler. If the necessary files are not found in the default directory, you may search elsewhere using the
standard Browse button.
Figure 4-5: Selecting the .SOP File Using the Browse Button
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The system type information is used to search for a proper directory file to use during compilation. The type
information is placed into the hex file so that the system program cannot be used in the wrong type of system (e.g.,
loading a Harmony system program into a 454 GT drive).
The compiler searches for the directory file in the current directory first. If it is not found there, the compiler provides a
browse function for finding an appropriate file. In all cases, the operator can verify that the intended file was used.
4.8 Output Hex File
Any inconsistencies that occur during the compilation process are flagged and error messages are displayed in a popup window. These error messages indicate the problem and lead the user towards problem resolution. Error messages
are listed in Table 4-6.
After successful processing, the third and final file is created. This is the hex file and it is named the same as the
source file with the extension changed to “.HEX.” The entire recompiled system program and is summed up in a
modulo 256 result that is inverted (2’s complement) and placed in the header of the compiled system program. This is
the system program checksum. The output is formatted in Intel 8086/8088 record format with a starting load offset of
0000. Each record consists of 16 bytes of data. Zeroes are appended to the final record for padding.
When interpreted as an Intel hex file by the drive during the download process, a binary image of the logic functions
results. These logic functions are stored and later executed by the drive. Each line of the hex file contains its own
checksum. In addition, the compiler generates an overall system program checksum. All of these checksums are
validated during system program downloading and restart to ensure correctness prior to storing the statements inside the
drive.
When downloaded into the drive, the system program is structured into sections. The first section is called the header
and contains system program location pointers, as well as the version number and the system program checksum.
The other sections concern the functionality of the system program and are not covered here.
4.9 Downloading a System Program (Hex File)
When the text for a system program has been created, and the text file has been compiled into a hex file using the
system program compiler, the resulting hex file must be downloaded into the drive to become functional. Software
embedded in the drive can be invoked to accept the properly formatted hex file into the drive using the RS232 serial port
as the transfer medium. The program can be downloaded in one of two methods:
1. Using the Upload/Download component of the Siemens LD A SOP Utilities software. This method can be
used by PCs that have at least Windows 2000 or later installed.
2. Using a terminal emulation program on the PC set up in ASCII file mode. This method can be used by PCs
that do not run Windows or have a Windows version before Windows 95 (using a DOSTM window). A native
Windows terminal emulator can also be used.
* Note: If you use the Siemens LD A SOP Utilities program to compile an SOP file that does not include
the #system_type; identifier, then the Product Type drop-down list is enabled, and you must select the
appropriate product type. This selection will then be compiled into the resulting hex file.
* Note: The DRCTRY.NGN file must adhere to certain syntax and format rules. Refer to Appendix A.
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4.9.1 Siemens LD A SOP Upload/Download Utility Method
The .HEX file must be downloaded using the Upload/Download component of the Siemens LD A SOP Utilities
program.
Figure 4-6: Siemens LD A SOP Utilities - Upload/Download Component
1. Invoke the Siemens LD A SOP Utilities program.
2. Select the Upload/Download tab.
3. Enter the HEX file to be downloaded.
4. Select the Download radio button.
5. Set the baud rate from the drop down box to 9600 baud.
6. Connect the appropriate serial port of the host PC to the DB9 port of the drive using an appropriate serial
cable (9-pin with appropriate connectors).
7. Select the “System Program Download” function menu (9120) of the drive. The drive will display download
status information on the front panel (e.g., “Downloading from RS232”). The drive will indicate when it
starts to receive data.
At the end of each hex line received, the drive will cause a bar in the last column of the keypad display to rotate to
indicate that data is being received. Each data record that follows is then checked against its own checksum and
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loaded at the appropriate address in RAM. Errors in a data record result in a displayed error message and termination of
the download process.
4.9.2 Terminal Emulation Method
The .HEX file must be downloaded with a terminal emulation program on the PC set up in ASCII file mode.
1. Set the baud rate (the same as drive’s baud rate parameter), parity (none), data bits (8) and stop bits (1) of the
communications software on the host PC, notebook, or laptop computer.
2. Connect the appropriate serial port of the host PC to the DB9 port of the drive using an appropriate serial
cable (9-pin with appropriate connectors).
3. “Enable” the communications software (i.e., prepare the software to either send information to the drive or
receive information from the drive). This basically puts the PC and communications software into a ready
state. Typical communications software packages include Microsoft Windows Terminal and Procomm-Plus
(only Windows 95™-compatible, if running this operating system).
4. Use the “System Program Upload” or “System Program Download” function from the Serial Functions
Menu (9110) of the drive to perform the desired function. The drive will display download status
information on the front panel (e.g., “Downloading from RS232”).
The drive will indicate when it starts to receive data. At the end of each hex line received, the drive will cause a bar in
the last column of the keypad display to rotate to indicate that data is being received. Each data record that follows is
then checked against its own checksum and loaded at the appropriate address in RAM. Errors in a data record result in a
displayed error message and termination of the download process.
4.9.3 Termination
Termination occurs when a valid “End Record” is received. If any error in transmission occurs, or if the user
manually “CANCELs” the transmission, the original system program will be copied back down from FLASH. If the
new program is accepted and reaches normal termination, it is then transferred from temporary RAM into nonvolatile FLASH storage, overwriting the original. The system program is then re-initialized with the new information,
and the system program is restarted, executing the new statements.
*
Note: Check the downloaded system program file for the proper version number. If the user tries to
download a system program that was compiled with the wrong DRCTRY.NGN file (for example, an
obsolete DRCTRY.DAT file), an error message will be displayed and the downloaded system program will
not be transferred to FLASH. Further, the system will not run a motor if, on power-up, the software
detects a system program checksum error or an out-of-range system program version stored in the
FLASH. To use an older system program in a drive with newer software, the system program must be
recompiled with the newer DRCTRY.NGN file before it is downloaded.
*
Note: Check the downloaded system program file for the proper version number. If the user tries to
download a system program that was compiled with the wrong DRCTRY.NGN file (for example, an
obsolete DRCTRY.DAT file), an error message will be displayed and the downloaded system program will
not be transferred to FLASH. Further, the system will not run a motor if, on power-up, the software
detects a system program checksum error or an out-of-range system program version stored in the
FLASH. To use an older system program in a drive with newer software, the system program must be
recompiled with the newer DRCTRY.NGN file before it is downloaded.
*
Note: To cancel the download process during the system program download, a [SHIFT]+[CANCEL]
key sequence can be entered from the drive’s keypad to terminate the download process and restore the
system to its original state.
Since the system program execution must be stopped while downloading a new system program, the
drive cannot be running during the download process.
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Table 4-6: Compiler Error Messages
Error Message Description
DRCTRY Error
ERROR in line nnnn - << flag name>> is longer than 43 characters.
The error occurred in the Directory file.
While loading, the system program flag found that the directory file is too
long. The offending flag and its line number in the directory file are listed. The
directory file is probably corrupted. Get the latest version and try again.
DRCTRY Error
ERROR in line nnnn - << flag name>> can'
t find system
address.
While loading the directory file, the compiler can’t determine the system
address. The flag name and error line number points to the source of the error.
The directory is probably corrupted. Get the latest and try again.
DRCTRY Error
ERROR in line nnnn!! <
t find bit address.
While loading the directory file, the bit address cannot be determined. The file
is probably corrupt. The flag name and line number should show where the
corruption occurs.
Replace the directory file and try again.
DRCTRY Error
ERROR in line nnnn!! <
t find type code.
While loading the directory file, the flag type cannot be determined. The file is
probably corrupted. The flag name and line number should show where the
corruption occurs.
Replace the directory file and try again.
SOP Error
ERROR!! User Text text flag defined multiple times.
The user text assignment flag displayed has been used multiple times in the
system program. Find the occurrences and correct them, then recompile.
SOP Error
ERROR!! Expecting '\' found >> CR or LF <<
The compiler was expecting an end quotation mark and found an end of line
instead. The error location will show in another popup window at the end. Edit
the source program and try again.
SOP Error
ERROR!! User Text flag ID is longer than 24 characters.
User Text must not exceed 24 characters - the limit on the keypad directory.
Edit the source file and try again.
SOP Error
ERROR!! Expecting '\' found >> character <<.
The compiler was expecting an end quotation mark but found another
character instead. Locate the error by the line number shown in an error popup
window, edit the file, and try again.
SOP Error
ERROR!! Expecting '=' found >> flag name <<.
The compiler is looking for the assignment operator and found another flag.
This is usually caused by improper use of the statement terminator, the semicolon, or the comment indicator--also a semi-colon.
SOP Error
ERROR!! opcode>> token name << not supported.
The compiler has parsed the source code and found a “token” it interprets as an
opcode, but is not an acceptable operator (“=”, “+”, “*”, “/”, or “;”). Check the
file and try again.
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Error Message Description
SOP Error
ERROR! Timer enable flag name cannot be set false.
The timer flag shown was set to false. This will never do anything and is
therefore displayed as an error.
SOP Error
ERROR! Counter reset flag name cannot be set true or false.
Setting the counter reset flag that is named prevents proper operation of the
counter. The name of the reset flag is displayed to help find the error.
SOP Error
ERROR! Counter enable flag name cannot be set true or false.
Counters count transitions from low to high. Setting the counter to true or false
renders the counter useless and is thus displayed as an error. The offending
flag name is displayed.
SOP Error
ERROR!! input>> flag name << is not an input type.
The flag named is not defined as an input only flag and cannot be used as an
input (on the right side of the equals sign).
SOP Error
ERROR!! Expecting ';' found >> flag name <<.
This error is usually displayed when the preceding logic statement is not
properly terminated by a semi-colon.
SOP Error
ERROR!! input>> flag name << not in directory.
The input flag named is not found in the directory file. Check the spelling and
try again.
SOP Error
ERROR!! Expecting '=' found >>flag name <<.
The compiler is expecting the assignment operator as it is parsing what it
thinks is a new logic statement. Check the syntax in the preceding statement,
edit the file, and try again.
SOP Error
ERROR!! attempt to redefine output >> flag name <<.
An output flag has a logic statement assigned to it (it is used on the left side of
the assignment operator) more than once. Find and change the offending line
and recompile.
SOP Error
ERROR!! output >> flag name < The flag named is not defined as an output only flag, and cannot be used as an output (on the left side of the equals sign). SOP Error ERROR!! output name>> flag name << not in directory. The output flag on the left of the equals sign is not found. Check the spelling of the flag name shown and try again. SOP Error ERROR!! Too Many Timers and Counters (Max 128 combined). There is a fixed number of timers and counters that can be used in any system program. The limit is 128 for the total of both timers and counters. Try to reduce the number of either timers or counters and compile again. SOP Error ERROR!! Drty name < in drty file The flag named as an alias is not found in the directory file. This is an advanced feature of the new compiler being released with the version 2.5 drive software, but will work with version 2.4 software. Define statements that can be used for more user-friendly names of functions, and substituted for fixed names. SOP Error ERROR!! < System program flag names are limited to 43 characters, and are truncated to that number. A flag longer than this is probably caused by a typo. Find and fix the error and recompile. SOP Error ERROR! A timer or counter (flag name) must be defined as an output before being used as an input! Timers and Counters are unique system flags. They require storage space for intermediate values for time or count, and additional space for storing their preset, enable logic state, reset, and output status flag. Therefore, the Timer or Counter must logically be assigned (on the left of the equals sign) before the status flag (the timer or counter name without the value) can be used as an input flag (to the left of the equals sign). SOP Error ERROR!! input scan table is full The storage space for the number of inputs is limited to the assignment of unique inputs. The limit for NXG is 800 entries. A flag is assigned only once even if used multiple times (as an input). NXG SOP Utilities NXG ToolSuite Software User Manual 4-24 902291: Version 3.0 s 4 Error Message Description SOP Error ERROR!! Counter reset ( counter. A counter must be defined as an output first! A reset flag is a unique flag used for resetting counters, but due to the storage situation as described above, a reset flag cannot appear in a system program before the counter is defined as an output (to the left of the equals sign). If the logic for the reset must appear before the definition, the use of a temporary flag to define the logic state can appear before the Counter, with the reset flag assigned to the temporary flag. Rewrite the logic and recompile. SOP Error ERROR!! output scan table is full The output scan table can contain a maximum of 800 unique entries. Timers and counters are created in the output scan table even if they are used as an input. These are the entries that map an I/O table location to the real world source (memory location, hardware output, etc.). And only one is required for each flag used. Bit flags take up 8 spaces even if only one is used. SOP Error ERROR!! input scan table is full The input scan table can contain a maximum of 800 unique entries. These are the entries that map an input flag from the real world source to the I/O table. Only one entry is required for each flag used. Bit flags take up 8 spaces even if only one is used. SOP Error ERROR!! logic table is full. The logic table can contain a maximum of 5000 total entries. The entries are created by logic statements as strings of inputs and outputs in sequential order separated by their operators. Each input, output, and operator used counts as an entry. SOP Error ERROR!! The maximum time for a single timer is 16383.5 secs! (4.55 hours) The amount of time assigned to a timer exceeded the max value allowed. This value applies for NXG software only. SOP Error ERROR!! The maximum count for a counter is 32767! The number of low to high transitions required to activate the output of a counter has been exceeded. Reduce the number in the parentheses and recompile. SOP Error ERROR!! expecting ) got>> name << Timers and counters, when they are defined, must have the flag name followed by a value enclosed in parentheses. The trailing parenthesis is missing. SOP Error ERROR!! expecting (got>> name << Timers and counters, when they are defined, must have the flag name followed by a value enclosed in parentheses. The compiler expected a left parenthesis as the next character. SOP Error ERROR!! System Program size (nnnn bytes) is greater than allowed (8192 bytes) The total storage size of the system program, listed in bytes, exceeds the max allowed space. This is the actual bytes used and not the size of the Intel Hex file, which is an ASCII representation of the data within a header, load information, and checksum error checking. SOP Error WARNING...Unable to load complete directory! Too many flags in directory (nnnn) The size of the directory file has exceeded the allocated memory for storing that file. Check the version of the compiler to ensure you are using the latest. Also check the directory file. SOP Error WARNING!! flag name has been redefined as an output on statement: nnnn line:nnnn. An output flag has a logic statement assigned to it (it is used on the left side of the assignment operator) more than once. Find and change the offending line and recompile. The second usage of the flag is located by the statement or line number. SOP Error WARNING!! Timer/counter >>flag name<< logic is redefined in line nnnn. This is the same as redefining output flags, but is specific to timers or counters. The line number shows the attempted redefinition. NXG ToolSuite Software User Manual NXG SOP Utilities 902291: Version 3.0 4-25 4 s 4.10 Uploading a System Program (Hex File) In a manner similar to downloading a system program, the system program can be uploaded from the drive to a receiving computer (binary format in the drive, hex format from the drive or compiler). This can permit archival of a functioning system program. Also, the text statements in a system program can be re-created so that the program can be examined or modified as needed. Using a similar method as described in the download section, invoke the serial communications upload function on the drive. If using the DOS-based upload utility, invoke the data capture process of the communications software prior to starting the data upload function in the drive. From the drive keypad, enter the “System Program Upload” function menu (9130). Once this function has been invoked, the keypad will indicate that the drive is uploading data. Most serial communications packages will display the ASCII hex data while it is being uploaded so that the upload process can be monitored. Once complete, the drive will indicate that it has finished and will return to the System program upload menu (9130). At this point, the data capture process in the PC is stopped and the resulting file is saved. 4.11 Reverse Compiler Because the system program embedded in the drive is in a non-readable form, a program to reverse compile the hex records of a system program back into readable statements was created. A reverse compiled program can be examined for logic functions and even edited, recompiled, and re-downloaded into the drive to alter the system program functionality as needed. Since the embedded hex file does not contain any symbolic information, a directory file within range is needed during the reverse compile process to convert from the binary address information back into symbolic readable form. The Siemens SOP Utilities program contains an integrated Reverse Compiler program. This component is similar to the compile component. A HEX file and DRCTRY file must be specified. If they do not exist in the default directory, locate the necessary files. When the appropriate files are specified, press the reverse compilation. See Figure 4-7. Reverse Compiler errors are listed in Table 4-7. Error Message Description No output file created. There is a warning message in the file. It needs to be commented out or removed before recompiling. Edit The error occurred in logic statement: nnn, line: nnnn. This is a special error that only occurs after a reverse compiled file is recompiled. The reverse compilation process inserted a warning message. This message needs to be reviewed before proceeding. Based on the message, it may be simply a matter of deleting the warning, or it could require rewriting portions of the system program. This file was created by the reverse compiler from a corrupt HEX file or utilizing the wrong DRCTRY file. No output file created. Edit source file name and try again. The error occurred in logic statement: nnnn, line: nnnn. If a corrupted hex file is reverse compiled, or if the wrong directory file was used in that process, there are usually “UNDEFINED” flags in the source file. If this is the case, the program will have to be rewritten. It is ALWAYS advisable to use source files instead of reverse compiled files so that changes can be documented, and the logic is described via the comments in the original file. The location of the compiler error is shown as both the statement and line number. * Note: As with the download, the upload process can be terminated from the drive side by entering a [SHIFT]+[CANCEL] key sequence. NXG SOP Utilities NXG ToolSuite Software User Manual 4-26 902291: Version 3.0 s 4 Figure 4-7: Reverse Compiler Options Window NXG ToolSuite Software User Manual NXG SOP Utilities 902291: Version 3.0 4-27 4 s Select hex file (contains valid source code): Information on file (Information button): Directory version button: NXG SOP Utilities NXG ToolSuite Software User Manual 4-28 902291: Version 3.0 s 4 Results of Rev Compile button when source code is embedded: Loaded hex file with no source code (in this case with same Directory versions for compile and reverse compile): NXG ToolSuite Software User Manual NXG SOP Utilities 902291: Version 3.0 4-29 4 s Pushing Rev Compile to generate the reverse compiled (*.dis) file rather than simply extracting the source. Loaded hex file with no source code (in this case with differences in Directory versions also). NXG SOP Utilities NXG ToolSuite Software User Manual 4-30 902291: Version 3.0 s 4 Loaded hex file – information button (Hex File) Version button (DRCTRY File) Push Rev Compile button (hex file has no embedded source and contains errors): NXG ToolSuite Software User Manual NXG SOP Utilities 902291: Version 3.0 4-31 4 s Go back to Compiler option and load created reverse compiled program to look for errors. Load file in editor – look at header and errors. NXG SOP Utilities NXG ToolSuite Software User Manual 4-32 902291: Version 3.0 s 4 4.12 Header #NEXTGEN; !!!!!!!!!!!!!!!!!!!!!!!!!!!! Warning !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! The version of DRCTRY.NGN used is DIFFERENT from the original DRCTRY Probable errors will occur, check the output files (You must comment these lines out before recompiling) !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! ; Siemens LD A ; ID Series System Program Reverse Compiler Windows Ver. 6.6.2 12/12/05 ; ; REVCMP Directory File Name : C:\PROJECTS\NXG4.0\FLASH\DRCTRY.NGN ; REVCMP used DRCTRY.NGN ver : 4.28 ; Hex File Name : Sop.hex ; System Program Name : NOWAGO.SOP ; System Program Date/Time : May 25 15:26:52 2000 ; System Type : NEXTGEN ; Hex file used DRCTRY version : 1.00 Errors in statements: TempFlag01_O = TempFlag01_O * /UNDEFINED * /UNDEFINED * TempFlag02_O + UNDEFINED * TempFlag02_O + UNDEFINED * TempFlag02_O; TempFlag02_O = TempFlag03_O * UNDEFINED; Table 4-7: Reverse Compiler Error Messages Error Message Description Hex File Error Too many input table entries (> 800) Then number of distinct inputs in the scan table exceeds the maximum allowable 800 entries. The hex file is possibly corrupted or is of the wrong drive type. Hex File Error Too many output table entries (> 800) Then number of distinct outputs in the scan table exceeds the maximum allowable 800 entries. The hex file is possibly corrupted or is of the wrong drive type. Hex File Error Too many logic table entries (> 5000) The number of entries in the logic table exceeds the maximum allowable 5000 entries. The hex file is possibly corrupted or is of the wrong drive type. Hex File Error Too many counter/timer entries (> 128) The hex file contains too many timers and counters (total sum of both) which cannot exceed 128 for NXG. The hex file is possibly corrupted or is of the wrong drive type. NXG ToolSuite Software User Manual NXG SOP Utilities 902291: Version 3.0 4-33 4 s DRCTRY Error ERROR in line nnnn - << flag name>> is longer than 43 characters. The error occurred in directory file name. The flag name shown is longer than the max allowable 43 characters. Check the flag indicated and check for a corrupted hex file. !!!!!!!!!!!!!!!!!!!!Warning!!!!!!!!!!!!!!!!!!!!!!! This file is corrupted (bad system program checksum). Carefully check all logic equations for invalid or undefined flags, erroneous timer or counter values, wrong use of flags, erroneous logic, etc. Edit these lines (and comment these warning lines), compile and use at your own risk. !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! This error message is added to the top of a reverse compiled program when the stored system program checksum does not compare with the calculated one. The file must be check for integrity, any errors corrected, and this comment removed before re-compiling. Since the checksum is invalid, the file may or may not work properly. DRCTRY Version Error The version of directory file name used is DIFFERENT from the original DRCTRY. Probable errors will occur, check the output files. (You must comment the warning lines out in the ‘ .DIS’ file before recompiling). This message will display if the version with which the system program is reverse compiled is different from the version used to create the original hex file. A warning will be added to the file along with the statistics of the compiler version and directory version, along with other information on the file. !!!!!!!!!!!!!!!!!!!!!!!Warning !!!!!!!!!!!!!!!!!!!!!!!!! The version of directory file name used is DIFFERENT from the original DRCTRY Probable errors will occur, check the output files (You must comment these lines out before recompiling) !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! ; Siemens LD A Group ; ID Series System Program Reverse Compiler version Number ; REVCMP Directory File Name : directory file name ; REVCMP used directory file name ver: n.nn ; Hex File Name : hex file name ; System Program Name : system program name ; System Program Date/Time: time/date ; System Type : drive type ; Hex file used DRCTRY version : n.nn This header is added to the top of the reverse compiler output file when the directory version error displays. The comments must be removed before the file can be recompiled successfully. Error Message Description NXG SOP Utilities NXG ToolSuite Software User Manual 4-34 902291: Version 3.0 s 4 The output file will contain a source statement for each original statement in the system program. The statements will be ordered with the invariant statements first, followed by the dependent statements. All of the statements in a section will be in the same order as the original file, with the exception of any true/false type statements which are moved to the front of the file. Error Message Description The file was reverse compiled successfully. Original DRCTRY file version: n.nn. Current DRCTRY file version: n.nn. Number of counters and timers: nnn. Number of in items: nnn. Number of out items: nnn. Number of logic items: nnnn. Header continuation. Hex File Error The hex file is corrupted. nn UNDEFINED label(s) found. Output file created anyway. Check file for error(s). The hex file used as the input to the reverse compiler was corrupted in some manner, creating UNDEFINED labels - labels that could not be found in the directory file. It may simply be that the directory file used to reverse compile did not contain the flags found. This error occurs anytime there is one or more “UNDEFINED” labels found. Source Corrupt This file is a dual source/hex file, but the source is corrupt. Do you want to try to reverse compile using the older method? This message occurs only with embedded source file information in the hex file. If the source file exists, the reverse compiler simply extracts the source text directly. If the end of file is not found within the source text, it is assumed corrupted and prompts the user to do an actual reverse compiler of the compiled code. No Errors The SOP source has been successfully extracted from the hex file. This message displays if the source text exists within the hex file and is successfully extracted. * Note: Comments from the original source file are not included in a compiled hex file and therefore cannot be reverse compiled. (See Section 4.13 on combined source and Hex files.) A copy of the symbol directory file (e.g., DRCTRY.NGN) must exist within the working directory of the compiler and reverse compiler, or in the directory of the invoked executable program. NXG ToolSuite Software User Manual NXG SOP Utilities 902291: Version 3.0 4-35 4 s 4.13 Combined Source / Hex File Beginning with NXG software version 2.4, the system is capable of accepting a combined source/hex file format. The older style compiled sop files. However, when reverse compiling, this new file format undergoes a pseudo reverse compiling process rather than the traditional reverse compiling process. In this pseudo reverse compiling process, all the original source comments and formatting is presented to the user as the reverse compiled output. This combined file type must be created or reverse compiled with SOP Utilities version 5.0 or later. In all other respects, this type of compiled sop is the same as the older file version. For example: Original SOP File #NEXTGEN; ; ---------------------------------------------------------------------------- ; Siemens LD R NEXT GEN HARMONY AC MOTOR DRIVE ; SYSTEM OPERATING PROGRAM (TEST VERSION) ; Program Number: NoWago.sop Customer: Siemens Siemens Sales Order: xxxx Siemens Part Numbers: xxxx ; Description: none ; Engineer: JAB ; ; Original Version Date: 10/31/00 --------------------------------------------------------------------------- ; ;SYMBOL DEFINITION ;--------------------------------------------------------------------------- ; = equals * logical AND+ logical OR / logical NOT ; ; comment line ;--------------------------------------------------------------------------- ; ;INITIALIZED FLAGS ;------------------------------------------------------------------------------ ; Keypad Speed reference RawDemandKeypad_O= TRUE; ; Speed profile SpeedProfile_O= FALSE; RunRequest_O = TempFlag01_O * TempFlag02_O; Ram pStop_O = TempFlag02_O; ; ; Fault Reset ; DriveFaultReset_O = KeypadFaultReset_I + ToolFaultReset_I; ;======================================================================= ;================================ END OF FILE=========================== ;======================================================================= NXG SOP Utilities NXG ToolSuite Software User Manual 4-36 902291: Version 3.0 s 4 Old Style .hex File Data :020000020000FC :1 000000046005F00800065008A0001 04AC009B464A :10001 0004E4F5741 474F2E534F50000000000000F5 :100020000000000000000000204465632031 3920FA :1 000300030393A34333A31 30203230303200000037 :10004000A20006009E0024020300012502040001 14 :1000500041 0007000F450008000F000000000000ED :100060000008010009030004040006020001040066 :100070000605000107000208000606000100000056 :100080001 3000000012E000100014000020001 5495 :10009000000500014900060001 000000000000000A :0C00A0009E0000000000000000009E001 8 :0000000 1FF Old Style Reverse Compiled Output #NEXTGEN; ; Siemens LD R Group ; ID Series System Program Reverse Compiler Windows Ver. 5.0.0 12/3/02 ; REVCMP Directory File Name : C:\PROGRAM FILES\Siemens\FLASH FILES\DRCTRY.NGN REVCMP used DRCTRY.NGN ver: 0401 ; Hex File Name : nowago.hex System Program Name : NOWAGO.SOP System Program Date/Time : Dec 19 09:43:10 2002 ; System Type : NEXTGEN ; Hex file used DRCTRY version : 0401 RawDemandKeypad_O = TRUE; SpeedProfile_O= FALSE; RunRequest_O= TempFlag01_O * TempFlag02_O; RampStop_O= TempFlag02_O; DriveFaultReset_O = KeypadFaultReset_I + ToolFaultReset_I; New Style .hex File :020000020000FC :1 000000046005F00800065008A0001 04AC009B464A :10001 0004E4F5741 474F2E534F50000000000000F5 :100020000000000000000000204465632031 3920FA :1 000300030393A34333A31 30203230303200000037 :10004000A20006009E0024020300012502040001 14 :1000500041 0007000F450008000F000000000000ED :100060000008010009030004040006020001040066 :100070000605000107000208000606000100000056 :100080001 3000000012E000100014000020001 5495 :10009000000500014900060001 000000000000000A :0C00A0009E0000000000000000009E001 8 :00000001 FF <1 ><2 1 6>Start-of-source <2><1 29>#NEXTGEN; <3><1 61>;------------------------------------------------------------ <4><23>;SIEMENS NEXT GEN HARMONY AC MOTOR DRIVE <5><1 30>;SYSTEM OPERATING PROGRAM (TEST VERSION) <6><74> NXG ToolSuite Software User Manual NXG SOP Utilities 902291: Version 3.0 4-37 4 s <7><235>;Program Number: NoWago.sop <8><157>;Customer: Siemens <9><255>; Siemens Sales Order: xxxx <10><94>; Siemens Part Numbers: xxxx <11><115>;Description: none <12><121>;Engineer: JAB <13><69>; <14><59>; Original Version Date: 10/31/00 <15><206>;-------------------------------------------------------------- <16><36>;SYMBOL DEFINITION <17><206>;--------------------------------------------------------------- <18><69>; <19><71>;= equals* logical AND+ logical OR / logical NOT <20><251>; ; comment line <21 ><69>; <22><14>;---------------------------------------------------------------- <23><8>;INITIALIZED FLAGS <24><206>;--------------------------------------------------------------- <25><101>; <26><163>; Keypad Speed reference <27><65>RawDemandKeypad_O= TRUE; <28><1 0> <29><103>; Speed profile <30><157>SpeedProfile_O= FALSE; <31><10> <32><87>RunRequest_O = TempFlag01_O * TempFlag02_O; <33><1 98>RampStop_O = TempFlag02_O; <34><69>; <35><132>; Fault Reset <36><69>; <37><30>DriveFaultReset_O = KeypadFaultReset_I + ToolFaultReset_I; <38><1 0> <39><219>;========================================================================== <40><206>;================================ END OF FILE ============================== <41 ><21 9>;========================================================================== <42><1 0> <43><240>End-of-file NXG SOP Utilities NXG ToolSuite Software User Manual 4-38 902291: Version 3.0 s 4 New Style Reverse Compiled Output #NEXTGEN; ;---------------------------------------------------------------------------------- ; SIEMENS NEXT GEN HARMONY AC MOTOR DRIVE ; SYSTEM OPERATING PROGRAM (TEST VERSION) ; Program Number: NoWago.sop ; Customer: Siemens Siemens Sales Order: xxxx Siemens Part Numbers: xxxx ; Description: none ; Engineer: JAB ; ; Original Version Date: 10/31/00 ;----------------------------------------------------------------------------------------- ;SYMBOL DEFINITION ;---------------------------------------------------------------------------------------- = equals * logical AND+ logical OR / logical NOT ; ; comment line ; ;------------------------------------------------------------------------------- ;INITIALIZED FLAGS ;------------------------------------------------------------------------------------------ ; ; Keypad Speed reference RawDemandKeypad_O= TRUE; ; Speed profile SpeedProfile_O= FALSE; RunRequest_O = TempFlag01_O * TempFlag02_O; RampStop_O = TempFlag02_O; ; ; Fault Reset ; DriveFaultReset_O = KeypadFaultReset_I + ToolFaultReset_I; ;============================================================================== ;================================ END OF FILE ================================= ;============================================================================== NXG ToolSuite Software User Manual NXG SOP Utilities 902291: Version 3.0 4-39 4 s Original SOP File #NEXTGEN; ;------------------------------------------------------------------------------------- ; Siemens LD R NEXT GEN HARMONY AC MOTOR DRIVE ; SYSTEM OPERATING PROGRAM (TEST VERSION) ; Program Number: NoWago.sop Customer: Siemens Siemens Sales Order: xxxx Siemens Part Numbers: xxxx ; Description: none ; Engineer: JAB ; ; Original Version Date: 10/31/00 ;-------------------------------------------------------------------------------- ;SYMBOL DEFINITION ;-------------------------------------------------------------------------------- ; ; = equals * logical AND+ logical OR / logical NOT ; ; comment line ; ;---------------------------------------------------------------------------------------- INITIALIZED FLAGS ;---------------------------------------------------------------------------------------- ; ; Keypad Speed reference RawDemandKeypad_O= TRUE; ; Speed profile SpeedProfile_O= FALSE; RunRequest_O = TempFlag01_O * TempFlag02_O; RampStop_O = TempFlag02_O; ; ; Fault Reset ; DriveFaultReset_O = KeypadFaultReset_I + ToolFaultReset_I; ;========================================================================== ;================================ END OF FILE============================= ;========================================================================= NXG SOP Utilities NXG ToolSuite Software User Manual 4-40 902291: Version 3.0 s 4 Old Style .hex File Data :020000020000FC :1 000000046005F00800065008A0001 04AC009B464A :10001 0004E4F5741 474F2E534F50000000000000F5 :100020000000000000000000204465632031 3920FA :1 000300030393A34333A31 30203230303200000037 :10004000A20006009E0024020300012502040001 14 :1000500041 0007000F450008000F000000000000ED :100060000008010009030004040006020001040066 :100070000605000107000208000606000100000056 :100080001 3000000012E000100014000020001 5495 :10009000000500014900060001 000000000000000A :0C00A0009E0000000000000000009E001 8 :0000000 1FF Old Style Reverse Compiled Output #NEXTGEN; ; Siemens LD A Group ; ID Series System Program Reverse Compiler Windows Ver. 5.0.0 12/3/02 ; REVCMP Directory File Name : C:\PROGRAM FILES\Siemens\FLASH FILES\DRCTRY.NGN REVCMP used DRCTRY.NGN ver: 0401 ; Hex File Name : nowago.hex System Program Name : NOWAGO.SOP System Program Date/Time : Dec 19 09:43:10 2002 ; System Type : NEXTGEN ; Hex file used DRCTRY version : 0401 RawDemandKeypad_O = TRUE; SpeedProfile_O= FALSE; RunRequest_O= TempFlag01_O * TempFlag02_O; RampStop_O= TempFlag02_O; DriveFaultReset_O = KeypadFaultReset_I + ToolFaultReset_I; New Style .hex file :020000020000FC :1 000000046005F00800065008A0001 04AC009B464A :10001 0004E4F5741 474F2E534F50000000000000F5 :100020000000000000000000204465632031 3920FA :1 000300030393A34333A31 30203230303200000037 :10004000A20006009E0024020300012502040001 14 :1000500041 0007000F450008000F000000000000ED :100060000008010009030004040006020001040066 :100070000605000107000208000606000100000056 :100080001 3000000012E000100014000020001 5495 :10009000000500014900060001 000000000000000A :0C00A0009E0000000000000000009E001 8 :00000001 FF <1 ><2 1 6>Start-of-source <2><1 29>#NEXTGEN; <3><1 61>;--------------------------------------------------------------------- <4><23>;SIEMENS NEXT GEN HARMONY AC MOTOR DRIVE <5><1 30>;SYSTEM OPERATING PROGRAM (TEST VERSION) NXG ToolSuite Software User Manual NXG SOP Utilities 902291: Version 3.0 4-41 4 s <6><74> <7><235>;Program Number: NoWago.sop <8><157>;Customer: Siemens <9><255>; Siemens Sales Order: xxxx <10><94>; Siemens Part Numbers: xxxx <11><115>;Description: none <12><121>;Engineer: JAB <13><69>; <14><59>; Original Version Date: 10/31/00 <15><206>;---------------------------------------------------------------- <16><36>;SYMBOL DEFINITION <17><206>;---------------------------------------------------------------- <18><69>; <19><71>;= equals* logical AND+ logical OR / logical NOT <20><251>; ; comment line <21 ><69>; <22><14>;------------------------------------------------------------------ <23><8>;INITIALIZED FLAGS <24><206>;---------------------------------------------------------------- <25><101>; <26><163>; Keypad Speed reference <27><65>RawDemandKeypad_O= TRUE; <28><1 0> <29><103>; Speed profile <30><157>SpeedProfile_O= FALSE; <31><10> <32><87>RunRequest_O = TempFlag01_O * TempFlag02_O; <33><1 98>RampStop_O = TempFlag02_O; <34><69>; <35><132>; Fault Reset <36><69>; <37><30>DriveFaultReset_O = KeypadFaultReset_I + ToolFaultReset_I; <38><1 0> <39><219>;======================================================================== <40><206>;================================ END OF FILE =========================== <41 ><219>;======================================================================== <42><1 0> <43><240>End-of-file NXG SOP Utilities NXG ToolSuite Software User Manual 4-42 902291: Version 3.0 s 4 New Style reverse Compiled Output #NEXTGEN; ;--------------------------------------------------------------------------------- ; SIEMENS NEXT GEN HARMONY AC MOTOR DRIVE ; SYSTEM OPERATING PROGRAM (TEST VERSION) ; Program Number: NoWago.sop ; Customer: Siemens Siemens Sales Order: xxxx Siemens Part Numbers: xxxx ; Description: none ; Engineer: JAB ; ; Original Version Date: 10/31/00 ;--------------------------------------------------------------------------------- ;SYMBOL DEFINITION ;------------------------------------------------------------------------- = equals * logical AND+ logical OR / logical NOT ; ; comment line ; ;---------------------------------------------------------------------------------- ;INITIALIZED FLAGS ;---------------------------------------------------------------------------------- ; ; Keypad Speed reference RawDemandKeypad_O= TRUE; ; Speed profile SpeedProfile_O= FALSE; RunRequest_O = TempFlag01_O * TempFlag02_O; RampStop_O = TempFlag02_O; ; ; Fault Reset ; DriveFaultReset_O = KeypadFaultReset_I + ToolFaultReset_I; ;========================================================================= ;================================ END OF FILE ============================ ;========================================================================= ∇ ∇ ∇ NXG ToolSuite Software User Manual NXG Configuration Update Utility Overview 902291: Version 3.0 5-1 5 s The Configuration Update Utility allows updating and configuration of software for the NXG CompactFlash card and the NXG ToolSuite. This utility is intended for use by trained Siemens personnel only. The Configuration Update Utility is a Microsoft Windows based application for creating or updating CompactFlash and ToolSuite software for the NXG control. When purchased, a CompactFlash memory card needs to be configured and made “bootable” for the real-time operating system that the NXG control uses. 5.1 System Requirements The NXG Configuration Update Utility is a Microsoft Windows application requiring the .NET 2.x Framework. It requires Windows 98/NT4.0/2000/XP, at least 128 MB of RAM, and a minimum of 15 MB of disk space. 5.2 Starting and Configuring the Configuration Update Utility Select the Utilities tab and click on the Configuration Update button as shown below: The Configuration Update Utility dialog box should appear as shown below: CHAPTER 5 NXG Configuration Update Utility Overview NXG Configuration Update Utility Overview NXG ToolSuite Software User Manual 5-2 902291: Version 3.0 s 5 5.3 Features Overview The Configuration Update Utility features currently available are: • Copy setup files to another directory • Update flash disk files • Make bootable default disk • Copy files from flash disk to PC • Make bootable copied disk • Update ToolSuite Host files on PC 5.3.1 Copy Setup Files to Another Directory This feature copies and overwrites the files from the source folder to the destination folder. The source folder can be a source, remote or local, to the PC being used. The typical output folder location is your local hard drive. This feature is mainly used by laptop users who want to load the latest software and files onto their laptops. Copy Setup Files to Another Directory 1. Select “Copy setup files to another directory.” 2. Click the “Select Source Folder” button. * Note: This feature will overwrite the existing destination files (i.e., on your local hard drive). Never use this feature with the CompactFlash disk as the destination drive or folder. NXG ToolSuite Software User Manual NXG Configuration Update Utility Overview 902291: Version 3.0 5-3 5 s 3. Select the location of the files you want to copy: 4. After picking the source folder, click the “OK” button. 5. Select the “Select Destination Drive or Folder” button. 6. Typically, “Select Output Directory” should point to “C:\Program Files\Robicon\Flash Files.” Clicking the “Local Hard Drive Copy” button will select this location. 7. After picking the output directory, click the “OK” button. 8. Now click the “Start” button on the Configuration Update dialog box (not shown). 9. A dialog box will appear to confirm that you are about to overwrite the existing files. Click “Yes.” 10. If the operation is successful, a confirmation dialog box will appear. Press “OK” to finish. * Note: Never use this feature with the CompactFlash disk as the destination drive or folder. NXG Configuration Update Utility Overview NXG ToolSuite Software User Manual 5-4 902291: Version 3.0 s 5 5.3.2 Update Flash Disk Files This feature allows the user to update files from a source folder location (which contains newer versions of NXG software) to the CompactFlash. The source folder can be a remote or local source to the PC being used. The output folder location is the CompactFlash card used in the NXG control. This feature updates the NXG software and configuration files, while maintaining the existing drive settings and system programs. Update Flash Files Procedure 1. Click the “Select Source Folder” button. 2. Select the location of the files that are of a newer or a later version than you currently have on the CompactFlash. The “Local Hard Drive Copy” button will pick the location “C:\Program Files\Robicon\Flash Files.” 3. After picking the source folder, click the “OK” button. 4. Click the “Select Destination Drive or Folder” button. 5. Typically, the “Select Output Drive” will be the CompactFlash card. 6. After picking the output directory, click the “OK” button. 7. Now click the “Start” button on the Configuration Update dialog box. 8. If the operation was successful, a confirmation dialog box will appear. Click “OK” to finish. 9. You can now insert the CompactFlash into the NXG CPU board. 5.3.3 Make Bootable Default Disk Procedure This feature allows the user to make a “bootable” CompactFlash disk that contains all of the software and configuration files necessary to run the drive (except for the system program). The source folder can be a source that is remote or local to the PC being used. The typical output drive is the CompactFlash card used in the NXG control. This feature is necessary when a new CompactFlash disk is used for the first time. * Note: This feature can only be used on an existing CompactFlash or directory that already contains files that may be older than the current release. Be certain to back these files up before proceeding with this operation. * Note: This feature will completely reformat the entire CompactFlash and write all of the necessary files for NXG control. If the CompactFlash contains files that are to be kept, then care should be taken to back these files up before proceeding with this operation. NXG ToolSuite Software User Manual NXG Configuration Update Utility Overview 902291: Version 3.0 5-5 5 s Make Bootable Default Disk Procedure 1. Select the Operation Type: “Make bootable default disk.” 2. Click the “Select Source Folder” button. 3. Select the location of the files that are of a newer or a later version than those currently on the CompactFlash. The “Local Hard Drive Copy” button will pick the location “C:\Program Files\Robicon\Flash Files.” 4. After picking the source folder, click the “OK” button. 5. Click the “Select Destination Drive or Folder” button. 6. The “Select Output Drive” will be the CompactFlash card. 7. After picking the output directory, click the “OK” button. 8. Now click the “Start” button on the Configuration Update dialog box. 9. If the operation was successful, a confirmation dialog box will appear. Click “OK” to finish. 10. You can now insert the CompactFlash into the NXG CPU board. NXG Configuration Update Utility Overview NXG ToolSuite Software User Manual 5-6 902291: Version 3.0 s 5 5.3.4 Copy Files from Flash Disk to PC This feature is for extracting a version of software from preprogrammed CompactFlash disks to use as a source for updating or making other CompactFlash disks. It copies all of the files from the CompactFlash disk and places them into the destination folder, typically on a PC. 1. Select the Operation Type: “Copy files from flash disk to PC.” 2. Click the “Select Source Folder” button. 3. Select the drive letter of the CompactFlash. 4. After selecting the source folder, press the “OK” button. 5. Click the “Select Destination Drive or Folder” button. 6. Select the location to where the Flash files are to be copied. Selecting the “Flash Copy Folder” will place the files in “C:\Program Files\Robicon\Flash Copy.” 7. After selecting the Destination Drive or Folder, click the “OK” button. 8. Now click the “Start” button on the Configuration Update dialog box. 9. A dialog box will appear to confirm that you are about to overwrite the existing files. Click “Yes.” 10. If the operation was successful, a confirmation dialog box will appear. Click “OK” to finish. 5.3.5 Make Bootable Copied Disk Procedure This feature allows the user to duplicate flash disks. This feature formats and makes a “bootable” CompactFlash disk that contains all of the software and configuration files necessary to run the drive (including the system programs). The source folder can be a source that is remote or local to the PC being used. Typically the source will be the flash copy folder. The typical output drive is the CompactFlash card used in the NXG control. * Note: This feature will completely reformat the entire CompactFlash and write all of the necessary files for NXG control. If the CompactFlash contains files that are to be kept, then care should be taken to back these files up before proceeding with this operation. NXG ToolSuite Software User Manual NXG Configuration Update Utility Overview 902291: Version 3.0 5-7 5 s Make Bootable Default Disk Procedure 1. Select the Operation Type: “Make bootable copied disk.” 2. Click the “Select Source Folder” button. 3. Select the source location for the Flash files. Selecting the “Flash Copy Folder” will select the files in “C:\Program Files\Robicon\Flash Copy.” 4. After selecting the Source Drive or Folder, click the “OK” button. 5. Click the “Select Destination Drive or Folder” button (not shown). 6. The location determined by “Select Output Drive” must be the CompactFlash card. 7. After selecting the Destination Drive or Folder, press the “OK” button. 8. Now click the “Start” button on the Configuration Update dialog box. 9. A dialog box will appear to confirm that you are about to write over the existing files. Click “Yes.” The files will be copied to the CompactFlash disk. While processing, a dialog box will appear telling you to “Please wait while processing!” 10. If the operation is successful, a confirmation dialog box will appear. Click “OK” to finish. 11. You can now insert the CompactFlash into the NXG CPU board. NXG Configuration Update Utility Overview NXG ToolSuite Software User Manual 5-8 902291: Version 3.0 s 5 5.3.6 Update ToolSuite Host Files on PC This feature updates the configuration files for all ToolSuite Configured drives. Each configuration must contain a default subfolder to be properly updated. If only a single configuration is to be updated, select the appropriate subfolder directly before starting. 1. Select the Operation Type: “Update ToolSuite host files on PC.” 2. Click the “Select Source Folder” button. 3. Select the location of the source files. 4. After selecting the source folder, click the “OK” button. 5. Click the “Select Destination Drive or Folder” button (not shown). 6. Clicking the “Tool Host Folder” button will place the files in “C:\Program Files\Robicon\Host.” 7. After selecting the Destination Drive or Folder, click the “OK” button. 8. Now click the “Start” button on the Configuration Update dialog box. 9. A dialog box will appear to confirm that you are about to overwrite the existing files. Click “Yes.” 10. If the operation is successful, a confirmation dialog box will appear. Press “OK” to finish. ∇ ∇ ∇ NXG ToolSuite Software User Manual Operators and Precedence 902291: Version 3.0 A-1 s A A.1 Operators and Precedence There are two forms of operators that can be used in a source line of the system program. These forms are unary operators (requiring only a single operand) and binary operators. There is a single unary operator: the negate operator. This operator takes the form of a slash character (“/”) which precedes a single input symbol. This operator forms the inverse logic equivalent of the symbol immediately following it for incorporation into the statement evaluation. It has higher precedence than the binary operators, which means it is evaluated before the evaluation of any binary operations. For example, the expression: /Zero_O equates to: NOT Zero_O. If the input variable “Zero_O” were FALSE, then “/Zero_O” would equate to TRUE. There are two binary operators: AND and OR. These operators take the form of an asterisk (“*”) and a plus sign (“+”), respectively. These operators correspond to the Boolean AND and OR functions. Unlike the unary NOT operator (which requires only a single variable), each of these operators requires two variables, which surround the operator. The binary operators “+” and “*” serve to form the simple Boolean combination of the combined expression preceding the operator and the symbol (possibly negated) immediately following the operator. Parentheses are not allowed to force expression evaluation. The expression must be formed with left to right precedence and must be expanded to simple form. Refer to the Boolean truth tables in Table A-1 for functional descriptions of the operators. Table A-2 shows the precedence of operations. Table A-3 shows syntax examples. Table A-1: Boolean Truth Table for the NOT, AND and OR Functions APPENDIX A Operators and Precedence * Note: The “/” symbol must be followed by an input symbol. NOT Function AND Function OR Function A /A A B A*B A B A+B False True False False False False False False True False False True False False True True True False False True False True True True True True True True Operators and Precedence NXG ToolSuite Software User Manual A-2 902291: Version 3.0 s A Table A-2: Precedence of Operations Table A-3: Syntax Examples The term “sum-of-products” comes from the application of Boolean algebraic rules to produce a set of terms or conditions that are grouped in a fashion that represents parallel paths (ORing) of required conditions that all must be met (ANDing). This would be equivalent to branches of connected contacts on a relay logic ladder that connect to a common relay coil. In fact, the notation can be used as a shortcut to describe the ladder logic. First let us examine the rules of Boolean algebra. The set of rules that apply in this logical math are broken into three sets of laws: commutative, associative, and distributive. The operators are “AND” (abbreviated with the “·” character [or “*” character from the keyboard]), “OR” (abbreviated with the “+” character), and “NOT” (abbreviated with a line above the operand, e.g., A [or a preceding “/” character from the keyboard]). The commutative, associative, and distributive rules are shown in Table A-4. Type of Operation Symbol Meaning Precedence Unary Operation / Not High (performed first) Binary Operation * And : Binary Operation + Or Low (performed last) Example Description C = A + B; Correct, C equals A OR B C = A * B + D; Correct, C equals (A AND B) OR D C = A + B * D; Correct, C equals A OR (B AND D) C = A * B + A * D; Correct, C equals (A AND B) OR (A AND D) C = A * (B + D); Incorrect, parentheses not allowed C = A + /B; Correct, C equals A OR (NOT B) /C = A * B; Incorrect, negation not permitted on output side NXG ToolSuite Software User Manual Operators and Precedence 902291: Version 3.0 A-3 s A Table A-4: Boolean Laws Table A-5: General Rules of Boolean Math Add to this DeMorgan's Theorem which states “the complement of the intersection (AND) of any number of sets equals the union (OR) of their complements” which, simply stated, means that if you invert a grouping of elements, you invert the individual elements and also change the logical relationship between them. So you can change from an OR to an AND function, for example: (A + B) = (A · B) or from an AND to an OR function, for example: (A · B) = (A + B) By using these rules, any logical statement can be reduced to the sum (+) of products (·) or the ORing of ANDed terms as illustrated in the following example: O = AB + BCD + CDF; The SOP file, as mentioned above, is written with a text editor or a word processor set for pure ASCII text (having an .TXT file extension) with no control or formatting codes with the exception of horizontal tabs (ASCII code 09h) and carriage returns (0Dh). Only printable characters and spaces (20h) can be used. The file consists of the following format: Commutative1 1. The syntax “AB” implies (A · B) Associative1 Distributive1 A + B = B + A A + (B + C) = (A + B) + C A (B + C) = AB + AC AB = BA A (BC) = (AB) C General Rules General Rules General Rules1 1. The syntax “AB” implies (A · B) A · 0 = 0 A + 0 = A A + AB = A A · 1 = A A + 1 = 1 A (A + B) = A A · A = A A + A = A (A + B) (A + C) = A + BC A · A = 0 A + A = 1 A + AB = A + B = A = A Operators and Precedence NXG ToolSuite Software User Manual A-4 902291: Version 3.0 s A A.2 Ladder Logic Translation It was mentioned above that the sum-of-products notation can represent ladder logic. In actuality, it is very easy to directly translate between the two. For example, consider the equation or statement: Z = ABC + DEF + FGH; Translated into the notation of the limited ASCII characters available in a common text editor, the statement would read as follows (note that the components are separated at “ORs” and stacked for clarity). Z =/A*B*C + D*/E*F + F*G*H; Item Description Drive type specifier This must reside on the first line of the file prefixed with the pound sign (#) and followed with the name of the drive (in the case of Perfect Harmony, this would be #Harmony;) Header A comment field containing the following information: Title - Siemens LD A Perfect Harmony drive Program part number Customer name Sales order number and Siemens drive part number Drive description Original SOP date File name Engineer Name (Originator) Revision history (date and change description) Note: A comment is any text within the file, preceded by a semi-colon, which is used exclusively for informational purposes and is ignored by the compiler. Operators Comment field containing operators and symbols I/O specifier Comment field describing the system input and output flags as they relate to the external system. This would include any user faults and notes on menu settings, such as Comparator setups and XCL settings, as they apply to the system program (more on this later). These can (and should) be grouped logically to allow easy access to information and to make the SOP more understandable. User fault messages Assigns the text to be displayed when this particular user fault is activated. Main logic section All the equations and assignments for the configuration, annunciation, and operation of the drive. These should be logically arranged with careful consideration given to the order of evaluation of the equations. NXG ToolSuite Software User Manual Operators and Precedence 902291: Version 3.0 A-5 s A This statement can be pictorially represented by breaking each statement down in the following manner: 1. First, the output variable (in this case Z) is represented by a coil to the right of the ladder. 2. Second, each product term (the variables separated by the asterisk) is represented by a single line of contacts connecting to the coil. 3. All the product terms that are summed (separated by the plus sign) are represented by parallel paths to the same coil. 4. All non-inverted contacts are represented by normally open (NO) contacts, while the inverted terms are represented by normally closed (NC) contacts. The resulting ladder logic is illustrated in Figure A-1. Figure A-1: Ladder Logic Representation of a Boolean Expression - Example 1 Conversely, if the ladder logic shown in Figure A-2 is desired, it could be converted into a sum-of-products statement. The procedure would be the inverse of the previous, and is enumerated below. 1. First place the label of the output relay coil to the left, with an equals sign following. 2. Next, start in each path from left to the connection to the coil on the right, writing the label for each contact with the asterisk representing the AND or product operator in between. 3. In front of each NC contact, place a forward slash representing the inversion or NOT operator (shown in the equations as a bar over the variable name). 4. Repeat this for each parallel path using the OR (sum) operator (+) in between each grouping of product terms. 5. Finally, the statement is terminated by a semicolon to represent the end of the statement. Operators and Precedence NXG ToolSuite Software User Manual A-6 902291: Version 3.0 s A Figure A-2: Ladder Logic Representation of a Boolean Expression - Example 2 ∇ ∇ ∇ NXG ToolSuite Software User Manual Ethernet Connections 902291: Version 3.0 B-1 s B B.1 Direct Connection The direct connection is for either a single PC connected to the drive using a special Ethernet crossover cable, or a small network hub or switch connecting multiple drives to one or more PCs. B.1.1 Required Items for a Single Ethernet Direct Connection • Crossover patch cable: this allows you to connect directly with the drive without a hub or server (requires a coupler, as shown below): Solutions4sure, http://www.solutions4sure.com/, 800.595.9333, supplier no. SOL4 S878311 10/100BT CAT5 XOVER PATCH 3’ ORG 88468 S104652 RJ45 MODULAR COUPLER STRT R6G050 B.1.2 Required Items for a Single PC Multiple Drive Ethernet Connection Support • EtherFast 10/100 5 port HUB GLOBAL COMPUTER SUPPLIES, http://www.globalcomputer.com/eQZ25aqd/, 888.8GL.OBAL 302517 Linksys EtherFast 10/100 5pt WKGP Hub EFAH05W • Ethernet Cat5 Cable GLOBAL COMPUTER SUPPLIES, http://www.globalcomputer.com/eQZ25aqd/, 888.8GL.OBAL ZCC31805XX 25’ SNAG-PROOF Ethernet cable Cat5 RJ-45 (xx - choose color) APPENDIX B Ethernet Connections * Note: This configuration also allows for more than one PC. Tool Suite PC NXG Drive Control Crossover cable and coupler Tool Suite PC HUB or Switch NXG Drive Control NXG Drive Control Ethernet Connections NXG ToolSuite Software User Manual B-2 902291: Version 3.0 s B B.1.3 Configuring a PC to Work with a Direct Connection To make a direct connection work after its hardware components are in place, the PC’s network interface has to be properly configured. We recommend that you record your current network settings (i.e., IP address, subnet mask, gateway, etc.) so that you can restore them if necessary. From the Start Menu, select “Settings” and click “Control Panel” as shown below: Within the Control Panel, double click on the “Network” icon as shown below: * Note: The following screen captures were taken from Windows 95/98. Windows NT and 2000 have different procedures for the configuration of network parameters. NXG ToolSuite Software User Manual Ethernet Connections 902291: Version 3.0 B-3 s B Select the “TCP/IP ->” connection that your PC uses (there might be more than one): Click the “Properties” button and click “Specify an IP address” in the IP Address tab page: Table B-1: Addresses of PC and Drive Where a, b, m, n, x, and y can be integers between 0 and 255. Device IP Address PC a.b.m.n Drive a.b.x.y Ethernet Connections NXG ToolSuite Software User Manual B-4 902291: Version 3.0 s B First, set the IP addresses for both the drive and the PC. In a direct connection, you will need to set the IP addresses of both the PC running the ToolSuite, and for the drive as well. The addresses will not be completely arbitrary. We recommend that the first number of both addresses be between 128 and 191 for class B network settings. You may select class A or C settings, if desired. The connection will function regardless of the class settings. The first two numbers (octets) of the drive’s IP address must be the same as the first two numbers of the PC’s IP address. For example, if you assign 172.16.20.15 as the drive’s IP address, the PC’s IP address must be 172.16.x.y, where the combination of x and y must be different than 20.15. Set the drive’s IP address using keypad parameter ID 9310. Next, set the subnet mask for the PC and the drive. In the “Subnet Mask:” field of the IP Address page, enter a value of 255.255.0.0. This value is the default for a class B network. The subnet mask must be the same for both the PC and the drive. Set the drive’s subnet mask using keypad parameter ID 9320. Finally, set the gateway for the drive and the PC. Stay in the TCP/IP Properties dialog box. Click the “Gateway” tab. Assign a valid arbitrary address number to the PC’s gateway in the “New gateway:” field. This address can be arbitrary (i.e. 0.0.0.0) because a direct connection does not actually use a gateway. This virtual gateway that you are creating for the direct connection does not physically exist. It is only to satisfy the software. After you enter the gateway address here, go to the keypad on the front of the drive, and enter the same gateway address in parameter ID 9330. NXG ToolSuite Software User Manual Ethernet Connections 902291: Version 3.0 B-5 s B Click “OK” in the Gateway page. Click “OK” in the “Network” dialog box. Windows may ask you if would like to restart your computer so that the changes can take effect. Click “Yes” to restart. B.2 Troubleshooting the Network Interface This section helps with troubleshooting several common problems with the network interface configuration of a PC. You will not need this section if you have successfully configured your network connection as described in the previous section, and your PC has no problems communicating with the drive. A network interface may need to be configured more than once in its lifetime. Your PC’s network interface must be configured/reconfigured if: • It has a conflict • You change your network configuration • Your network interface driver has duplicate or multiple installations B.2.1 Changing Existing Network Configuration You might need to make changes to your network configuration occasionally. Some possible situations in which the change will be needed are listed below: • The computer running the ToolSuite is currently connected to the drive over the company’s LAN network, but you want to use a direct connection. A direct connection, for example, could be another small network with only two nodes, i.e., the ToolSuite running on a PC, and the embedded system in the drive. Alternatively, you may currently have a direct connection, and want to convert to a LAN. Such changes may require a different network configuration. • The computer running the ToolSuite software is currently configured for one network, i.e., a LAN, and you want to connect it to a different network, i.e., another LAN. In any of these instances, and in similar situations, you are switching between two different network configurations. In doing so, you may need to reconfigure your network interface. Reconfiguration requires two steps: 1. Disconnect from the current network connection (i.e., your company’s LAN). We recommend that you make records of the current configuration settings before you change them, so that you may restore them if necessary. 2. Configure and connect to the desired network as described in the previous section. Ethernet Connections NXG ToolSuite Software User Manual B-6 902291: Version 3.0 s B B.2.2 Resolving Conflict in Network Interface A conflict occurs if your computer has a network interface device that is configured incorrectly. Checking the resource settings for the network interface device may help you determine the type of resource conflict. Please try the following procedure, which may solve the problem: 1. Click Start, point to Settings, click Control Panel, and then double-click System. 2. On the Device Manager page, expand “Network adapters” by clicking on its adjacent plus sign. Select each network interface device (each entry under “Network adapters”) and click the “Properties” button. In the new dialog box, click the “General” tab. “Device status” may indicate if there are any problems with the device. The device in this example is working properly. NXG ToolSuite Software User Manual Ethernet Connections 902291: Version 3.0 B-7 s B Then click the “Resources” tab and look for the “Conflicting device list” at the bottom of the “Resources” page. If you see any problems listed under the “General” tab, or find any conflicting devices under the “Resources” tab, or if you find problems under both tabs, remove each effected device and re-install its driver. To remove and re-install the device: 1. Close this screen and go to the Device Manager. Select the conflicting device. 2. Click “Remove.” 3. Restart your computer. 4. During the system startup, you will be prompted to enter the disk that has the device driver program. Insert the disk. You will be prompted to restart the computer. 5. After your system is restarted, go to the device’s dialog box again. (In this example, it is “3com Ether link 10/100 PCI for complete management.” In other instances it will be similar to this example, except for the name of the vendor. Select the network interface device in the Device Manager, and click on the “Properties” button to arrive at this dialog box. (You should see “No conflicts” in the “Conflicting device list” under the Resources tab.) 6. Configure your newly installed network interface card as described in the previous section. This procedure will most likely solve your network problems. If you still experience problems after reinstallation, please contact your network administrator. B.2.3 Removing Duplicate or Multiple Occurrences in Device Manager The remove the duplicate occurrence: • Click Start, point to Settings, click Control Panel, and then double-click System. • On the Device Manager tab, look for duplicate devices. To remove all occurrences of the device: • Click Start, point to Settings, click Control Panel, and then double-click System. • On the Device Manager tab, click an occurrence of the device, and then click “Remove.” • Repeat the above step for each remaining occurrence of the device. Ethernet Connections NXG ToolSuite Software User Manual B-8 902291: Version 3.0 s B • Restart the computer, and reinstall the driver for the network interface device. If you don’t have a driver, the following might work: • Click Start, point to Settings, click Control Panel, and then double-click System. • On the Device Manager tab, look for duplicate devices. To remove extra occurrences of the device: • Click Start, point to Settings, click Control Panel, and then double-click System. • On the Device Manager tab, click one occurrence of the device, and then click “Remove.” Repeat the above step for each remaining occurrence of the device, until only the active occurrence is left, and then click “Close.” • Restart your computer. • In Control Panel, double-click System, and then click the Device Manager tab. Make sure the device is listed only once. Once you are sure that the device appears only once on the Device Manager tab, check its resource settings. To view the resource settings: • Click Start, point to Settings, click Control Panel, and then double-click System. • On the Device Manager tab, double-click the device. • Click the Resources tab, and then verify that you are viewing the resource settings for the correct device. • Close the dialog box. The computer will no longer have duplicate entries for any network interface devices. The network interface devices should function properly. ∇ ∇ ∇ * Note: If the Resources tab does not appear, the device is not using any resources. Contact the device manufacturer about a possible hardware conflict. NXG ToolSuite Software User Manual Glossary 902291: Version 3.0 C-1 s C This appendix contains definitions of terms and abbreviations used throughout the Perfect Harmony series manuals. AND - AND is a logical Boolean function whose output is true if all of the inputs are true in SOP notation, AND is represented as “∗” (e.g., C=A∗B), although sometimes it may be omitted between operands with the AND operation being implied (e.g., C=AB). ASCII - ASCII is an acronym for American Standard Code for Information Interchange, a set of 8-bit computer codes used for the representation of text. Baud rate - Baud rate is a measure of the switching speed of a line, representing the number of changes of state of the line per second. The baud rate of the serial port of the Perfect Harmony is selected through the Baud Rate parameter in the Communications Menu [9]. Bit - Bit is an acronym for BInary digiT. Typically, bits are used to indicate either a true (1) or false (0) state within the drive’s programming. Boolean algebra - A form of mathematical rules developed by the mathematician George Boole used in the design of digital and logic systems. Carrier frequency - Carrier frequency is the set switching frequency of the power devices (IGBTs) in the power section of each cell. The carrier frequency is measured in cycles per second (Hz). “Catch a spinning load” feature - “Catch a spinning load” is a feature that can be used with high-inertia loads (e.g., fans), in which the drive may attempt to turn on while the motor is already turning. This feature can be enabled via the NXG menu system. CLVC - An acronym for Closed Loop Vector Control - which is one of six control modes in the NXG drive. This is flux vector control for an induction machine (IM), utilizing an encoder for speed feedback. CMP - Refer to the glossary term SOP. Comparator - A comparator is a device that compares two quantities and determines their equality. The comparator submenus allow the programmer to specify two variables to be compared. The results of the custom comparison operations can be used in the system program. Configuration Update - see ToolSuite definition. Converter - The converter is the component of the drive that changes AC voltage to DC voltage. Critical speed avoidance - Critical speed avoidance is a feature that allows the operator to program up to 3 mechanical system frequencies that the drive will “skip over” during its operation. CSMC - An acronym for Closed Loop Synchronous Machine (SM) Control. One of six control modes of the NXG drive. This is a flux vector control for a synchronous machine, utilizing an encoder for speed feedback and providing a field excitation command for use by an external field exciter. Debug Tool - see ToolSuite definition. DC link - The DC link is a large capacitor bank between the converter and inverter section of the drive. The DC link, along with the converter, establishes the voltage source for the inverter. De Morgan’s Theorem - The duality principal of Boolean algebra used to convert system logic equations into sumof-products notation. Downloading - Downloading is a process by which information is transmitted from a remote device (such as a PC) to the drive. The term “downloading” implies the transmission of an entire file of information (e.g., the system program) APPENDIX C Glossary Glossary NXG ToolSuite Software User Manual C-2 902291: Version 3.0 s C rather than continued interactive communications between the two devices. The use of a PC for downloading requires special serial communications software to be available on the PC, which may link to the drive via RS232 or through the Host Simulator via an ethernet connection. DRCTRY - Directory file for system tokens and flags used in the compilation of system programs. It provides a direct lookup table of ASCII names to internal ID numbers. It also identifies whether the flag is a word or bit-field, and also whether it can be used as an input or output only, or can be used for both. Drive - The term “drive” refers to the power conversion equipment that converts utility power into power for a motor in a controlled manner. ELV - ELV is an acronym for extra low voltage, and represents any voltage not exceeding a limit that is generally accepted to be 50 VAC and 120 VDC (ripple free). EMC - EMC is an acronym for electromagnetic compatibility–the ability of equipment to function satisfactorily in its electromagnetic environment without introducing intolerable electromagnetic disturbances to anything in that environment. ESD - ESD is an acronym for electrostatic discharge. ESD is an undesirable electrical side effect that occurs when static charges build up on a surface and are discharged to another. When printed circuit boards are involved, impaired operation and component damage are possible side effects due to the static-sensitive nature of the PC board components. These side effects may manifest themselves as intermittent problems or total component failures. It is important to recognize that these effects are cumulative and may not be obvious. Fault log - Fault messages are saved to memory so that the operator may view them at a later time. This memory location is called the fault log. The fault log lists both fault and alarm messages, the date and time that they occurred, and the time and date that they are reset. Faults - Faults are error conditions that have occurred in the Perfect Harmony system. The severity of faults vary. Likewise, the treatment or corrective action for a fault may vary from changing a parameter value to replacing a hardware component such as a fuse. Flash Card - Non-volatile memory storage device for the NXG control. It stores the drive program, system program, logs, parameters, and other related drive files. FPGA - Field Programmable Gate Array. An FPGA is an integrated circuit that contains thousands of logic gates. Function - A function is one of four components found in the Perfect Harmony menu system. Functions are built-in programs that perform specific tasks. Examples of functions include System Program Upload/Download and Display System Program Name. Harmonics - Harmonics are undesirable AC currents or voltages at integer multiples of the fundamental frequency. The fundamental frequency is the lowest frequency in the wave form (generally the repetition frequency). Harmonics are present in any non-sinusoidal wave form and cannot transfer power on average. Harmonics arise from non-linear loads in which current is not strictly proportional to voltage. Linear loads like resistors, capacitors, and inductors do not produce harmonics. However, non-linear devices such as diodes and silicon controlled rectifiers (SCRs) do generate harmonic currents. Harmonics are also found in uninterruptable power supplies (UPSs), rectifiers, transformers, ballasts, welders, arc furnaces, and personal computers. Hexadecimal digits - Hexadecimal (or “hex”) digits are the “numerals” used to represent numbers in the base 16 (hex) number system. Unlike the more familiar decimal system, which uses the numerals 0 through 9 to make numbers in powers of 10, the base 16 number system uses the numerals 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, and F to make numbers in powers of 16. Historic log - The historic log is a troubleshooting/diagnostic tool of the Perfect Harmony NXG control. The historic log continuously logs drive status, including the drive state, internal fault words, and multiple user-selectable variables. This information is sampled every slow loop cycle of the NXG control (typically 450 to 900 times per second). If a fault occurs, the log is frozen a predefined number of samples after the fault event, and data samples prior to and after the fault condition are recorded to allow post-fault analysis. The number of samples recorded are user-selectable via the NXG control, as well as the option to record the historic log within the VFD event log. NXG ToolSuite Software User Manual Glossary 902291: Version 3.0 C-3 s C Host Simulator - see ToolSuite definition. I/O - I/O is an acronym for input/output. I/O refers to any and all inputs and outputs connected to a computer system. Both inputs and outputs can be classified as analog (e.g., input power, drive output, meter outputs, etc.) or digital (e.g., contact closures or switch inputs, relay outputs, etc.). IGBT - IGBT is an acronym for Insulated Gate Bipolar Transistors. IGBTs are semiconductors that are used in the Perfect Harmony drives to provide reliable, high-speed switching, high-power capabilities, improved control accuracy, and reduced motor noise. Induction motor - An induction motor is an AC motor that produces torque by the reaction between a varying magnetic field (generated in the stator) and the current induced in the coils of the rotor. Intel hex - Intel hex refers to a file format in which records consist of ASCII format hexadecimal (base 16) numbers with load address information and error checking embedded. Inverter - The inverter is a portion of the drive that changes DC voltage into AC voltage. The term “inverter” is sometimes used mistakenly to refer to the entire drive (the converter, DC link, and inverter sections). Jog mode - Jog mode is an operational mode that uses a pre-programmed jog speed when a digital input (programmed as the jog mode input) is closed. Jumpers - Jumper blocks are groups of pins that can control functions of the system, based on the state of the jumpers. Jumpers (small, removable connectors) are either installed (on) or not installed (off) to provide a hardware switch. Ladder logic - (Also Ladder Diagram) A graphical representation of logic in which two vertical lines, representing power, flow from the source on the left and the sink on the right, with logic branches running between, resembling rungs of a ladder. Each branch consists of various labeled contacts placed in series and connected to a single relay coil (or function block) on the right. Loss of signal feature - The loss of signal feature is a control scheme that gives the operator the ability to select one of three possible actions in the event that the signal from an external sensor, configured to specify the speed demand, is lost. Under this condition, the operator may program the drive (through the system program) to (1) revert to a fixed, pre-programmed speed, (2) maintain the current speed, or (3) perform a controlled (ramped) stop of the drive. By default, current speed is maintained. LVD - LVD is an acronym for Low Voltage Directive, a safety directive in the EU. Lvl RH - This term refers the two security fields associated with each parameter of the system. These fields allow the operator to individually customize specific security features for each menu option (submenu, parameter, pick list, and function). These fields are shown in parameter dumps and have the following meanings. Lvl is the term for the security level. Setting R=1 blocks parameter change, and setting H=1 hides the menu option from view until the appropriate access level has been activated. Memory - Memory is the working storage area for the Perfect Harmony drive that is a collection of RAM chips. Microprocessor - A microprocessor is a central processing unit (CPU) that exists on a single silicon chip. The microprocessor board is the printed circuit board on which the microprocessor is mounted. The NXG drive employs a single-board computer with a Pentium® microprocessor. NEMA 1 and NEMA 12 - NEMA 1 is an enclosure rating in which no openings allow penetration of a 0.25-inch diameter rod. NEMA 1 enclosures are intended for indoor use only. NEMA 12 is a more stringent NEMA rating in which the cabinet is said to be “dust tight” (although it is still not advisable to use NEMA 12 in conductive dust atmospheres). The approximate equivalent IEC rating is IP52. Normally closed (NC) - Normally closed refers to the contact of a relay that is closed when the coil is de-energized. Normally open (NO) - Normally open refers to the contact of a relay that is open when the coil is de-energized. OLTM - An acronym for Open Loop Test Mode - One of six control modes of the NXG drive. Glossary NXG ToolSuite Software User Manual C-4 902291: Version 3.0 s C OLVC - An acronym for Open Loop Vector Control, also known as Encoderless Vector Control. OLVC is a flux vector control that is one of six control modes of the NXG drive. The drive computes the rotational speed of the rotor and uses it for speed feedback. OOS - OOS is an abbreviation for out of saturation - a type of fault condition in which a voltage drop is detected across one of the IGBTs during conduction. This can indicate that the motor is drawing current too rapidly or in excess. OR - OR is a logical Boolean function whose output is true if any of the inputs is true. In SOP notation, OR is represented as “+”. Parameter - A parameter is one of four items found in the Perfect Harmony menu system. Parameters are system attributes that have corresponding values that can be monitored or, in some cases, changed by the user. PED - PED is an acronym for pressure equipment directive, a directive of the EU relating to pressure vessels. Pick list - A pick list is one of four items found in the Perfect Harmony menu system. Pick lists are parameters that have a finite list of pre-defined “values” from which to choose, rather than a value range used by parameters. PID - PID is an acronym for proportional + integral + derivative, a control scheme used to control modulating equipment in such a way that the control output is based on (1) a proportional amount of the error between the desired setpoint and the actual feedback value, (2) the summation of this error over time, and (3) the change in error over time. Output contributions from each of these three components are combined to create a single output response. The amount of contribution from each component is programmable through gain parameters. By optimizing these gain parameters, the operator can “tune” the PID control loop for maximum efficiency, minimal overshoot, quick response time, and minimal cycling. Qualified user - A qualified user is a properly trained individual who is familiar with the construction and operation of the equipment and the hazards involved. Quick menu - Quick menu is a feature of the menu system that allows the operator to directly access any of the menus or parameters, rather than scrolling through menus to the appropriate item. This feature uses the [Shift] button in conjunction with the right arrow. The user is prompted to enter the four digit ID number associated with the desired menu or parameter. RAM - RAM is an acronym for Random Access Memory, a temporary storage area for drive information. The information in RAM is lost when power is no longer supplied to it. Therefore, it is referred to as volatile memory. Regeneration - Regeneration is the characteristic of an AC motor to act as a generator when the rotor’s mechanical frequency is greater than the applied electrical frequency. Relay - A relay is an electrically controlled device that causes electrical contacts to change their status. Open contacts will close and closed contacts will open when rated voltage is applied to the coil of a relay. RS232C - RS232C is a serial communications standard of the Electronics Industries Association (EIA). Setpoint - Setpoint is the desired or optimal speed of the VFD to maintain process levels (speed command). Slip - Slip is the difference between the stator electrical frequency of the motor and the rotor mechanical frequency of the motor, normalized to the stator frequency as shown in the following equation.: Slip =ω S - ω R ω S Slip is the force that produces torque in an induction motor. Slip can also be defined as the shaft power of the motor divided by the stator input power. Slip compensation - Slip compensation is a method of increasing the speed reference to the speed regulator circuit (based on the motor torque) to maintain motor speed as the load on the motor changes. The slip compensation circuit increases the frequency at which the inverter section is controlled to compensate for decreased speed due to load droop. For example, a motor with a full load speed of 1760 rpm has a slip of 40 rpm. The no load rpm would be 1800 rpm. If the motor nameplate current is 100 A, the drive is sending a 60 Hz wave form to the motor (fully loaded); then NXG ToolSuite Software User Manual Glossary 902291: Version 3.0 C-5 s C the slip compensation circuit would cause the inverter to run 1.33 Hz faster to allow the motor to operate at 1800 rpm, which is the synchronous speed of the motor. SMC - Is an acronym for Synchronous Motor Control - which is one of six control modes in the NXG drive.This mode computes the rotational speed similarly to open-loop vector control, and controls the field reference or the synchronous motor as in closed-loop synchronous motor control. SOP - (1) SOP is an acronym for Sum Of Products. The term “sum-of-products” comes from the application of Boolean algebraic rules to produce a set of terms or conditions that are grouped in a fashion that represents parallel paths (ORing) of required conditions that all must be met (ANDing). This would be equivalent to branches of connected contacts on a relay logic ladder that connect to a common relay coil. In fact, the notation can be used as a shortcut to describe the ladder logic. (2) SOP, when used as a filename extension, refers to System Operating Program. SOP Utilities - The program within the Siemens LD A ToolSuite used for converting between text and machine loadable code. It can also be used for uploading and downloading files over the RS232 connection. Stop mode - Stop mode is used to shut down the drive in a controlled manner, regardless of its current state. Submenus - A submenu is one of four components found in the Perfect Harmony menu system. Submenus are nested menus (i.e., menus within other menus). Submenus are used to logically group menu items based on similar functionality or use. Synchronous speed - Synchronous speed refers to the speed of an AC induction motor’s rotating magnetic field. It is determined by the frequency applied to the stator and the number of magnetic poles present in each phase of the stator windings. Synchronous Speed equals 120 times the applied Frequency (in Hz) divided by the number of poles per phase. System Operating Program - The functions of the programmable inputs and outputs are determined by the default system program. These functions can be changed by modifying the appropriate setup menus from the front keypad and display. I/O assignments can also be changed by editing the system program (an ASCII text file with the extension .SOP), compiling it using the compiler program, and then downloading it to the controller through its serial port, all by utilizing the SOP Utility Program with the Siemens LD A ToolSuite. SOP Utilities - see ToolSuite definition. ToolSuite - Is the suite of programs developed by Siemens that allows easier access to the NXG drive for programming and monitoring. It is comprised of the following components: • ToolSuite Launcher - also referred to as ToolSuite; used for coordinating other tools. • SOP Utilities - used to launch an editor that compiles or reverse compiles a System Program. It also allows for serial connection to the drive for uploading and downloading System Programs. • Configuration Update - allows for backing-up, updating, and cloning drives via direct access to the Flash Disk. • Host Simulator - used for monitoring, programming, and controlling a drive remotely from a PC over the built-in ethernet port of the drive. Parameter changes, status display, and graphing of internal variables are its main functions. • Debug Tool - this tool is used to display the diagnostic screens of the drive for diagnosing drive problems or improving performance via the built-in ethernet port of the drive. ToolSuite Launcher - see ToolSuite definition. Torque - The force that produces (or attempts to produce) rotation, as in the case of a motor. Uploading - Uploading is a process by which information is transmitted from the drive to a remote device such as a PC. The term uploading implies the transmission of an entire file of information (e.g., the system program) rather than continued interactive communications between the two devices. The use of a PC for uploading requires communications software to be available on the PC. Glossary NXG ToolSuite Software User Manual C-6 902291: Version 3.0 s C Variable frequency drive (VFD) - A VFD is a device that takes a fixed voltage and fixed frequency AC input source and converts it to a variable voltage, variable frequency output that can control the speed of an AC motor. VHZ - Is an acronym for Volts per Hertz control, one of six control modes in the NXG drive. This mode is intended for multiple motors connected in parallel. Therefore, it disables spinning load and fast bypass. This is essentially open-loop vector control with de-tuned (smaller bandwidth obtained by reducing the gain) current regulators. ∇ ∇ ∇ NXG ToolSuite Software User Manual Abbreviations 902291: Version 3.0 D-1 s D This appendix contains a list of symbols and abbreviations commonly used throughout this manual group. Commonly Used Abbreviations APPENDIX D Abbreviations Abbreviation Meaning • Boolean AND function + Addition or Boolean OR Summation µ Microsecond A Amp, Ampere AC Alternating Current accel Acceleration A/D Analog to Digital Converter ADC Analog to Digital Converter AI Analog Input alg Analog avail Available BIL Basic Impulse Level BTU British thermal units C Centigrade or Capacitor cap Capacitor CCB Cell Control Board ccw Counter clockwise CE Formerly European Conformity, now true definition CFM Cubic feet per minute CLVC Closed Loop Vector Control cmd Command com Common conn Connector CPS Control Power Supply CPU Central Processing Unit CSMC Closed Loop Synchronous Motor Control CT Current Transformer cu Cubic curr, I Current cw Clockwise D Derivative (PID), depth Σ Abbreviations NXG ToolSuite Software User Manual D-2 902291: Version 3.0 s D D/A Digital-to-analog (converter) db Decibel DC Direct Current DCR Digital Control Rack DCS Distributed Control System decel Deceleration deg, ° Degrees DHMS Down hole monitoring system div Division dmd Demand e Error EC Electrically Commutated ELV Extra Low Voltage EMC Electromagnetic Compatibility EMF Electromotive Force EMI Electromagnetic Interference EPS Encoder Power Supply ESD Electrostatic Discharge ESP Electrical Submersible Pump ESTOP, e-stop Emergency Stop fb, fdbk Feedback ffwd Feed Forward FLC Full Load Current freq Frequency ft, ' Feet fwd Forward GenIIIe Generation IIIe GenIV Generation IV gnd Ground GUI Graphical User Interface H Height H2O Water hex Hexadecimal hist Historic hp Horsepower hr Hour HV High Voltage HVAC Heating, Ventilation, Air Conditioning HVF Harmonic Voltage Factor Abbreviation Meaning NXG ToolSuite Software User Manual Abbreviations 902291: Version 3.0 D-3 s D Hz Hertz I Integral (PID) ID Identification IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronic Engineers IGBT Insulated Gate Bipolar Transistor in Input in, “ Inches INH Inhibit I/O Input(s)/Output(s) IOB I/O Breakout Board IOC Instantaneous Overcurrent IP Input Protection k 1,000 (e.g., Kohm) kHz KiloHertz kV Kilo Volts kVA One Thousand Volt Amps kW Kilowatt L Inductor LAN Local Area Network lbs Pounds (weight) LCD Liquid Crystal Display ld Load LED Light-emitting Diode LFR Latch Fault Relay lim Limit LOS Loss Of Signal lps Liters Per Second mA Milliamperes mag Magnetizing max Maximum MCC Motor Control Center mg Milligram min Minimum, Minute msec Millisecond(S) msl Mean Sea Level MV Medium Voltage mvlt Motor Voltage MW Megawatt Abbreviation Meaning Abbreviations NXG ToolSuite Software User Manual D-4 902291: Version 3.0 s D NC Normally Closed NEMA National Electrical Manufacturer’s Association NMI Non-Maskable Interrupt No Normally Open NVRAM Non-Volatile Random Access Memory NXG Next Generation Control NXG II Next Generation Control II oamp Output Current OLVC Open Loop Vector Control O-M Overmodulation OOS Out of Saturation (IGBT) overld Overload P Proportional (PID) Pa Pascals pb Push Button PC Personal Computer or Printed Circuit PCB Printed Circuit Board PID Proportional Integral Derivative PLC Programmable Logic Controller PLL Phase Locked Loop pot Potentiometer pp Peak-to-peak ppm Parts per Million PPR Pulses per Revolution PQM Power Quality Meter ProToPSTM Process Tolerant Protection Strategy PSDBP Power Spectral Density Break Point psi Pounds Per Square Inch pt Point PT Potential Transformer PWM Pulse Width Modulation Q1,Q2,Q3,Q4 Output Transistor Designations rad Radians RAM Random Access Memory ref Reference rev Reverse, Revolution(S) RFI Radio Frequency Interference RLBK Rollback rms Root-mean-squared Abbreviation Meaning NXG ToolSuite Software User Manual Abbreviations 902291: Version 3.0 D-5 s D RPM Revolutions Per Minute RTD Resistance Temperature Detector RTU Remote Terminal Unit RX Receive (RS232 Communications) s Second(s) SCB Signal Conditioning Board SCR Silicon Controlled Rectifier sec Second(s) ser Serial SMC Synchronous Motor Control SOP Sum of Products; System Operating Program spd Speed stab Stability std Standard sw Switch T1, T2 Output Terminals TI and T2 TB Terminal Block TBD To Be Determined TCP/IP Transmission Control Protocol/Internet Protocol THD Total Harmonic Distortion TOL Thermal Overload TP Test Point trq, τ Torque TX Transmit (RS232 Communications) UPS Uninterruptable Power Supply V Voltage, Volts VA Volt-Amperes VAC Volts AC var Variable VDC Volts DC vel Velocity VFD Variable Frequency Drive V/Hz Volts per Hertz vlts Voltage(s), Volts VSI Voltage Source Inverter W Width, Watts WAGO Expansion I/O System WCIII Water Cooled III xfmr, xformer Transformer Abbreviation Meaning Abbreviations NXG ToolSuite Software User Manual D-6 902291: Version 3.0 s D ∇ ∇ ∇ NXG ToolSuite Software User Manual Index Index 902291: Version 3.0 I-1 sA Abbreviations D-1 B Binary operators A-1 Bootable Copied Disk Procedure 5-6 Bootable Default Disk Procedure 5-4, 5-5, 5-7 C Change Default Editor 4-5 CMP C-1 Compilation error 4-8 Compile Process 4-7 Compiler C-1 Compiler Error Messages 4-22 Compiler Operation 4-18 Configuration Update Utility 5-1 Configuration Update Utility features 5-2 Configuring Drive Tool 2-4 Copy Setup Files 5-2 D Debug Tool 3-1 Direct Connection B-1, B-2 Directory Filename Associations 4-13 Downloading System Program 4-19 Drive configuration 2-1 Drive Configuration Features 2-1 Drive configurator 3-1 Drive Control Features 2-2 Drive name 3-1 Drive Status Features 2-2 Drive Tool Pull Down Menu 2-2 Drive Variable Graphing Features 2-1 E Electrostatic discharge vi EMC C-2 Error Message 4-32, 4-34 Ethernet (TCP/IP) Communications 2-5 Ethernet Connection B-1 Ethernet Connections B-1 Ethernet Direct Connection B-1 F Flag Names 4-17 Flash Disk 5-6 Flash Disk Files 5-4 Flash Files 5-4 Freeze On fault 2-13 Freeze on trigger 2-14 G Glossary C-1 Glossary of terms C-1 Graphing Display 2-9 H Header 4-32 I Input Flags 4-16 Input Source File 4-9 Installation 1-5 Installation Procedure 1-2 IP address 3-1, B-3 L List of symbols D-1 Lock-out/tag-out procedures v LVD C-3 M Multiple Occurrences in Device Manager B-7 N Network Configuration B-5 Network Interface Conflict B-6 Network Interface Troubleshooting B-5 Network settings B-2 New Drive 3-2 NXG Configuration Update Utility 5-1 NXG Debug Tool 3-1 NXG Drive Tool 2-1 NXG SOP Utilities 4-1 O Operating Debug Tool 3-2 Operating Drive Tool 2-7 Operators and Precedence A-1 Output Flags 4-16 Output Hex File 4-19 Overview 1-1 P PC and Drive Addresses B-3 PED C-4 Post Processing of Data 2-14 Precautions v Product type selector 4-11 Product Types 4-12 R Reverse Compiler 4-25 S Safety precautions v Index NXG ToolSuite Software User Manual I-2 902291: Version 3.0 s Safety precautions and warnings vi SOP Development Process 4-6 SOP Source File 4-13 SOP Text File Format 4-14 SOP Utility Terminology 4-2 SOP Utility Tool 4-1 SOP Utility Tool 4-4 Starting the Debug Tool 3-1 Successful compilation 4-8 Symbols D-1 System Requirements 3-1, 5-1 System Type Identification 4-11 System type identifier 4-11 T Target Directory 4-5 Target source file 4-5 Terminal Emulation Method 4-21 Termination 4-21 Termination 4-21 Tool Suite Host Files 5-8 Tool Suite installation 1-7 Tool Suite Setup 1-3 Tool Suite software components 1-4 U Unary operators A-1 Update Flash Disk Files 5-4 Upload/Download Utility Method 4-20 Uploading System Program 4-25 Utilities Tab 4-4 V Variables 2-10 W Warnings v Z Fault and Alarm Displays 2-7 NXG ToolSuite Software User Manual NOTES 902291: Version 3.0 N-1 s NOTES NOTES NXG ToolSuite Software User Manual N-2 902291: Version 3.0 s NXG ToolSuite Software User Manual NOTES 902291: Version 3.0 N-3 s NOTES NXG ToolSuite Software User Manual N-4 902291: Version 3.0 s∇ ∇ ∇ NXG ToolSuite Software User Manual Reader Comments Form 902291: Version 3.0 R-1 s Reader Comments Form To provide quality documentation that meets the needs of its customers, Siemens LD A invites comments and criticisms of this manual. Please complete the attached form and provide your comments on this manual. After completing this form, please remove this page from the manual (or photocopy it) and either mail, E-mail or fax it back to the Documentation Department at Siemens LD A. These are mechanisms through which you can positively effect the documentation that you receive from Siemens. Thank you for your feedback. It is always valued and appreciated. Did you find the manual well organized? { Yes { No Was the information presented clearly? { Yes { No Was the manual sufficiently illustrated? { Yes { No Did you find the material adequate? { Yes { No Would you prefer a more technical or less technical approach? { More { Less What improvements would you like to see? (Please be specific and cite examples, if possible.) Did you find any technical inaccuracies or mistakes? If so, please indicate page number(s) and information that needs to be corrected. What feature of the manual did you find the most useful? The least useful? Reader Comments Form NXG ToolSuite Software User Manual R-2 902291: Version 3.0 s Additional Comments Thank you for your comments. Please mail, fax or e-mail your comments to: Attention: Documentation Control Siemens LD A 500 Hunt Valley Road New Kensington, PA 15068 USA Phone: (724) 339-9500 Fax: (724) 339-9562 E-mail: [email protected] ∇ ∇ ∇ NXG ToolSuite Software User Manual Startup/Warranty Registration and Service Solutions 902291: Version 3.0 W-1 s Startup/Warranty Registration and Service Solutions To assure timely technical updates on your equipment, please complete and return this form. This information is to be completed by the end user or equipment owner. For information on post sale service solutions, please check the appropriate boxes below before returning this form to Siemens Energy & Automation,Inc. For additional information by phone, please complete the table above and check the appropriate items below: • Extended Warranty • Full Service Agreement • Preventative Maintenance Agreement • In-House Training at Siemens • On-Site Training at your Location • Spare Parts Kits Return this information to Siemens at the address below, or fax it to (724) 339-9562, or call the Technical Support Department at (724) 339-9501. Please visit our web site at www.siemens.com. Attention: Customer Service Operations Siemens LD A 500 Hunt Valley Road New Kensington, PA 15068 USA Company Name Contact Name Company Address Phone Fax E-mail Part Number (P/N) (see system door or system panel) Sales Order Number (SO #) (see system door or system panel) Start-up Date Start-up Completed by Startup/Warranty Registration and Service Solutions NXG ToolSuite Software User Manual W-2 902291: Version 3.0 s
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