GRUNDFOS INSTRUCTIONS CIU 850 Modbus-GRM-PLC Installation and operating instructions For the latest online version, visit Grundfos Product Center http://net.grundfos.com/qr/i/98490991 English (GB) English (GB) Installation and operating instructions 2. Definitions and abbreviations Original installation and operating instructions CONTENTS Page APN Access Point Name CIU Communication Interface Unit 1. Symbols used in this document 2 2. Definitions and abbreviations 2 3. Applications 2 4. Product description 3 5. 5.1 5.2 5.3 5.4 Installation Mechanical installation Connecting the data cables Electrical connection GRM commissioning 4 4 4 4 4 6. 6.1 6.2 6.3 Operation Communication status LEDs Ethernet status LEDs PLC CPU status LEDs 5 5 5 5 7. General data 5 8. Fault finding 6 PLC Programmable Logic Computer 9. Parts list 7 PLC CPU Central Processing Unit. 10. Disposal 7 TCP/IP Transmission Control Protocol/Internet Protocol. Protocol for Internet communication. Warning Prior to installation, read these installation and operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice. 1. Symbols used in this document Warning If these instructions are not observed, it may lead to electric shock with consequent risk of serious personal injury or death. Caution Note If these safety instructions are not observed, it may result in malfunction or damage to the equipment. Notes or instructions that make the job easier and ensure safe operation. CIU 850 CIU 850 Modbus-GRM-PLC GPRS General Packet Radio Service. Technology for TCP/IP communication and mobile Internet access. GRM Grundfos Remote Management HTTP Hyper Text Transfer Protocol. The protocol commonly used to navigate the World Wide Web. LED Light-emitting diode MicroSD Micro Secure Digital. A memory card format. Modbus RTU A serial communications protocol commonly used in industry and building automation systems. 3. Applications The CIU 850 is a gateway for connecting a Modbus RTU/TCP network to Grundfos Remote Management. Grundfos Remote Management Grundfos Remote Management is a web-based solution for monitoring and control of networks. It allows you to access information and control pumps remotely using an ordinary computer or mobile device. You must have a contract with Grundfos to access GRM. CIU 850 - Modbus RTU/TCP communication The gateway functions as a Modbus RTU/TCP master. It can be connected to Modbus RTU slave devices via a wireless radio or wired (serial) connection. A radio modem (SATELLINE-3AS or similar) is required for wireless connection. It can be connected to Modbus TCP slaves through a external wireless 3G or 4G router or via an RJ45 connector to the network. CIU 850 - GRM communication The CIU 850 communicates with GRM via an HTTP TCP/IP Ethernet connection. A connection and a network router with Internet access or a wireless modem (GPRS or similar) is required. 2 English (GB) 4. Product description 8 9 10 11 1 2 3 4 5 6 15 7 16 17 Fig. 1 TM05 8583 2113 12 13 14 Front view of the PLC CPU Pos. Description 1 Status LED of Ethernet port 1 2 RJ45 Ethernet port 1 3 Status LED of Ethernet port 1 4 Status LED of Ethernet port 2 5 RJ45 Ethernet port 2 Designation LED5 DATA1 LED6 LED7 DATA2 6 Status LED of Ethernet port 2 LED8 7 9-pin RS-485 serial port DATA3 8 Status LED 1 of CIU 850 LED1 9 Status LED 2 of CIU 850 LED2 10 Status LED 3 of CIU 850 LED3 11 Status LED 4 of CIU 850 LED4 12 Power LED of PLC CPU PWR 13 Earth connection of the PLC CPU GND 14 24 V power supply of the PLC CPU PSU 15 MicroSD card slot 1 16 Status LED of MicroSD 17 MicroSD card slot 2. Not used. SD1 HDD1 SD2 3 5. Installation 5.3 Electrical connection Warning During electrical installation, make sure that the power supply cannot be accidentally switched on. 5.1 Mechanical installation The 24 V power supply unit and the PLC CPU must be mounted on a DIN rail in a control cabinet. Caution 1. Check that all parts listed in section 9. Parts list are present. 2. Mount the DIN rail horizontally on a cabinet wall. Use the two M4 screws with washers for installation in a metal control cabinet. Use the two self-tapping screws for wooden or plastic walls. 3. Mount the PLC CPU on the DIN rail according to the installation and operating instructions for the PLC CPU. 4. Slide the PLC extension module onto the PLC CPU. 5. Check that both the top and bottom rails are connected and that the module has clicked onto the DIN rail. 6. Connect the power supply unit to the DIN rail, next to the PLC CPU. See the installation and operating instructions of the 24 V power supply unit. Leave a minimum gap of 5 mm on both sides of the unit. 5.2 Connecting the data cables Do not use the 24 V power supply unit for powering the serial adapter. The electrical installation must be carried out by an authorised person in accordance with local regulations and the relevant wiring diagram. TM05 8745 2613 Caution Fig. 3 Connection of the power supply 1. Connect the power supply unit to the PLC CPU using two wires supplied with the unit. Choose the colour according to your local regulations. 2. Connect a main supply cable to N, L and earth of the power supply unit. 3. If the 9-pin to 15-pin serial adapter is used, connect the red and black conductors to an additional 24 V power supply unit. The unit is not supplied with CIU 850. 5.4 GRM commissioning 1 3 2 Fig. 2 TM05 8638 2613 English (GB) If problems occur during installation, see section 8. Fault finding. Connecting the data cables 1. Connect the Ethernet cable to a network router or modem, and to an Ethernet port. Make sure the network is protected by a firewall. 2. Modbus RTU Connect the serial cable (RS 485) to the PLC CPU. If a radio Modbus network exists, use the 9pin to 15-pin serial adapter to connect the serial cable to your radio modem. 3. Modbus TCP Connect the network slaves to the other Ethernet port via a network cable (RJ45) or connect the 3G or 4G router. Setup the Router for closed APN and power router, a related SIM card with closed APN is also required for wireless router communication. 4 Note It may be necessary to map the Modbus profile via the GRM server, depending on the Modbus device connected. Contact Grundfos in case of newly connected device types. You must setup the GRM system online before data can be transferred. 1. Switch on the power. 2. Check that the LED of the 24 V power supply unit is on. 3. Check that the LEDs HDD1 and PWR of the PLC CPU are on and that one of the Ethernet LEDs (LED5 or LED7) is on or flashing. 4. Contact Grundfos for activation of your GRM account. 6. Operation Note Do not remove or replace the microSD card while the PLC CPU is switched on. The USB ports of the PLC CPU cannot be used for other USB devices. English (GB) Caution 6.2 Ethernet status LEDs The status LEDs are to the left of both Ethernet ports. See fig. 1. LED Description On or flashing Off LED5 Link activity, Ethernet port 1 Active Not active 100 Mbits/s 10 Mbits/s Active Not active 100 Mbits/s 10 Mbits/s The CIU 850 transfers data to GRM once the hardware installation and GRM commissioning have been completed. If the gateway to GRM could not be created or is lost, check the status of the LEDs. See sections 6.1 Communication status LEDs to 6.3 PLC CPU status LEDs and section 8. Fault finding. The GRM server monitors the GRM gateway and has basic knowledge about the status of the ModbusGRM PLC. It also ensures that the GRM gateway application is aligned with the GRM server and kept up-to-date. The CIU 850 software is stored on the microSD card in slot 1. 6.3 PLC CPU status LEDs 6.1 Communication status LEDs The PLC CPU has status LEDs on the front. See fig. 1. The PLC CPU extension module has four status LEDs showing the connectivity to the GRM server and to the Modbus devices. See fig. 1. LED Description Network LED6 speed, Ethernet port 1 LED7 Link activity, Ethernet port 2 Network LED8 speed, Ethernet port 2 LED Description On Off PWR HDD1 Power supply Active Not active MicroSD 1 Available Not available On Off Established once Never established 7. General data Connection to LED2 Modbus device Established Not established Permissible ambient temperature -25 °C - +60 °C LED3 GRM activity Active Not active Supply voltage [V] 100-240 AC Connection ok Connection lost Frequency [Hz] 50/60 Dimensions of DIN rail [mm] (w x h x d) 250 x 35 x 7.5 Dimensions of CIU 850 [mm] (w x h x d) as in fig. 3 209 x 100 x 111 Enclosure class IP20 Connection to LED1 GRM LED4 Connection to GRM 5 8. Fault finding English (GB) Fault (LED status) Possible cause Remedy 1. a) The microSD card is not inserted correctly in slot 1. Turn off the CIU 850, press on the microSD card and remove it from the slot. Re-insert the card in slot 1 and click it home. Turn on the CIU 850. b) There is no microSD card in slot 1, or the card is defective. Check if the microSD card has been inserted in slot 2 by mistake. For card replacement, find the product number in the parts list and contact the nearest Grundfos service centre. The LED of the power supply unit remains off when the power has been switched on. a) The power supply unit is defective. Connect another 24 V power supply unit to the PLC CPU. Contact the nearest supplier service centre. b) No power supply present. Check the main power supply and the fuse. The status LEDs show that the CIU 850 has never connected to GRM. See sections 6.1 Communication status LEDs and 6.2 Ethernet status LEDs. a) No GRM commissioning has taken place. Configure the GRM server according to section 5.4 GRM commissioning. b) The CIU 850 cannot connect to the Internet. Check that ports 80 and 443 of the Ethernet router, firewall and network are open for outbound traffic. c) The Ethernet cable is defective or not connected correctly. Check that both ends of the Ethernet cable are correctly inserted in the ports, and that LED5 is on. Replace the cable if necessary. The status LEDs show that the CIU 850 is not connected to Modbus RTU. See section 6.1 Communication status LEDs. a) The serial cable or 9-pin to 15-pin serial adapter is defective or not connected correctly. Check that both ends of the serial cable are correctly inserted in the ports or adapter. If a radio modem is used, check the external 24 V power supply of the radio modem. Replace the cable or adapter if necessary. b) The wires of the 9-pin to 15pin serial adapter are defective. Replace the adapter. c) Wrong configuration of the GRM account. Check that the configuration of GRM is correct. a) The Ethernet cable to the Modbus TCP slaves is not proper connected. Check the Ethernet cable connection to the Modbus TCP slaves. b) The Ethernet cable to the 3G/ Check the Ethernet cable connecting to the 4G router is not proper router and that the router is switched on and connected. correctly set. Verify that the SIM card fit to the router and uses the correct closed APN. 2. 3. 4. 5. 6 LED "PWR" is on and LED "HDD1" is off. The status LEDs show that the CIU 850 is not connected to Modbus TCP. See section 6.1 Communication status LEDs. Quantity Description English (GB) 9. Parts list Product number 1 Complete CIU 850 box 98502708 1 MicroSD card (pre-installed in slot 1 of the PLC CPU) 98516861 1 PLC CPU 1 PLC CPU extension module 1 Power supply unit, 24 VDC, 4 A 1 Red wire 2 Black wire 1 Ethernet cable with RJ 45 connectors (patch cable) 1 9-pin to 15-pin serial adapter with two wires for external 24 VDC 1 RS-485 serial cable (1.8 metres) 1 Installation and operating instructions for the 24 V power supply unit 1 Installation note for the PLC CPU and the extension module 1 DIN rail 2 M4 x 10 screw with washers 2 4.2 x 13 self-tapping screw 10. Disposal This product or parts of it must be disposed of in an environmentally sound way: 1. Use the public or private waste collection service. 2. If this is not possible, contact the nearest Grundfos company or service workshop. Subject to alterations. 7 Appendix 1 X000 X100 CX9020 X102 00 07 08 24V 0V 01 02 X0 PWR TC 0V 24V X001 X101 + + - - - - - - X103 RS232 RS485 X200 TxD+/RxD+ PE PE 03 04 EL2004 BECKHOFF DV1-D Txd-/RxD- TxD+ RxDRxD- RxD+ Txd-/RxD- 1 2 3 4 5 6 TxD+/RxD+ TM06 5644 5115 - TM06 5645 5115 HDD TM06 5643 5115 HDD BECKHOFF Appendix RS-422/RS485 connection (CX9020-N031) The CX9020-N030 system interface provides an RS 485 interface, COM1. It is implemented on a 9-pole Sub-D socket strip. To connect to ELSA deceives using RJ11 connectors, use the connection setup illustrated below: For RS 485 pins 2 and 3 (data +) must be connected, and pins 7 and 8 (data -). Pin assignment of the COM interface PIN Signal Type Description 2 TxD+ Data-Out + Transmit 422 3 RxD+ Data-In + Receive 422 5 GND Ground Ground 6 VCC VCC +5V 7 TxD- Data-Out - Transmit 422 8 RxD- Data-In - Receive 422 8 9 Appendix Declaration of conformity Declaration of conformity 2 EC/EU declaration of conformity We, Grundfos, declare under our sole responsibility that the product CIU 850, to which the declaration below relates, is in conformity with the Council Directives listed below on the approximation of the laws of the EC/EU member states. Note: There are two sets of Council Directives and standards listed below. One set applies until and including 19th April 2016. The other set applies from 20th April 2016 and onwards. These Directives and standards apply until and including 19th April 2016: – Low Voltage Directive (2006/95/EC). Standard used: EN 60950-1:2006 + A11:2009 + A1:2010 + A12:2012. – EMC Directive (2004/108/EC). Standard used: EN 61000-6-2:2005 and EN 61000-6-4:2005 + A1:2011. These Directives and standards apply from 20th April 2016 and onwards: – Low Voltage Directive (2014/35/EU). Standard used: EN 60950-1:2006 + A11:2009 + A1:2010 + A12:2011. – EMC Directive (2014/30/EU). Standard used: EN 61000-6-2:2015 and EN 61000-6-4:2005 + A1:2011. This EC/EU declaration of conformity is only valid when published as part of the Grundfos installation and operating instructions (publication number 98490991 0216). Bjerringbro, 26th November 2015 Technical Director GRUNDFOS Holding A/S Poul Due Jensens Vej 7 8850 Bjerringbro, Denmark Person authorised to compile technical file and empowered to sign the EC declaration of conformity. 10 China Hong Kong Bombas GRUNDFOS de Argentina S.A. Ruta Panamericana km. 37.500 Centro Industrial Garin 1619 Garín Pcia. de B.A. Phone: +54-3327 414 444 Telefax: +54-3327 45 3190 GRUNDFOS Pumps (Shanghai) Co. 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GRUNDFOS Pumps Corporation 17100 West 118th Terrace Olathe, Kansas 66061 Phone: +1-913-227-3400 Telefax: +1-913-227-3500 Uzbekistan Grundfos Tashkent, Uzbekistan The Representative Office of Grundfos Kazakhstan in Uzbekistan 38a, Oybek street, Tashkent Телефон: (+998) 71 150 3290 / 71 150 3291 Факс: (+998) 71 150 3292 Addresses Revised 25.01.2016 Grundfos companies ECM: 1175845 www.grundfos.com The name Grundfos, the Grundfos logo, and be think innovate are registered trademarks owned by Grundfos Holding A/S or Grundfos A/S, Denmark. All rights reserved worldwide. 98490991 0216 © Copyright Grundfos Holding A/S