background image

 

 

     2

 

            NRG User Manual | © 2020 | CARLO GAVAZZI LTD.  

V1.0 | NRG EtherCAT User Manual | © 2022 | CARLO GAVAZZI LTD. 

 

 EN

 

1.

 

Introduction 

1.1

 

Foreword 

 

The NRG described hereafter is a sub-system made up of a number of solid state relays intended for the switching of 

heaters in a machine. The solid state relays in this system are able to communicate with the main controller through 

an NRG controller that facilitates communication between the solid state relays and the main controller. The NRG 

controller is available with  various communication interfaces including EtherCAT, EtherNet/IP

TM

  and Modbus RTU.  

Through this communication, it is possible for the main controller to control each solid state relay, read measurements 

related to each specific solid state relay and to identify specific failure modes related to the solid state relay or its 

associated heater load. 

 

 

1.2

 

Scope   

 

 

This manual is intended to provide information about the functionalities that are provided by the NRG system, explains 

set-up and configuration procedures, provides recommendations for use and gives a troubleshooting guide. 

 

Should there be any problems that cannot be solved with the information provided in this guide, contact your Carlo 

Gavazzi sales representative for further assistance. 

 

1.3

 

Disclaimer 

 

Carlo Gavazzi accepts no liability for any consequence resulting from inappropriate, negligent, incorrect installation 

or adjustment of parameters of the equipment. Nor can Carlo Gavazzi assume liability for recommendations that 

appear or are implied in the following description. The information in this document is not considered binding on any 

product warranty. 

 

The contents of this guide are believed to be correct at the time of publishing. In the interests of commitment to a 

policy of continuous development and improvement, Carlo Gavazzi reserves the right to change the specification 

of the product or its performance, or the contents of this guide without prior notice. 

 

1.4

 

Warning notice system 

 

The symbols indicated below are used throughout this guide to indicate a particularly important subject or information 

on safety instructions, configuration and installation of the products covered by this guide. 

It is strongly recommended that this guide is read thoroughly before using the products and that safety related 

recommendations are followed. 

 

Danger  

Indicates that death, severe personal injury or property damage will result if proper precautions are not taken. 

 

Warning  

Indicates actions that if not observed may lead to damage of the products.

 

 

Information 

Indicates general information related to the proper use of the products. 

 

1.5

 

Qualified personnel 

 

The product / system described in this documentation may be operated only by personnel qualified for the specific 

task that are also capable of identifying risks and avoid potential hazards when working with these products. 

The NRG system features dangerous voltages and consequently failure to observe the instructions contend in this user 

manual may cause serious harm to people and damage to property. 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for NRG EtherCAT

Page 1: ...NRG EtherCAT User Manual Operating instructions Manuale d istruzioni Betriebsanleitung Manuel d instructions Manual de instrucciones Brugervejledning...

Page 2: ...ounding 10 4 EtherCAT Configuration 11 4 1 Installing the ESI file in TwinCAT 11 4 2 Integrating the NRG in TwinCAT 11 4 3 Configuration of the NRG bus chain in TwinCAT 13 4 4 Start up Parameters 14 5...

Page 3: ...equipment Nor can Carlo Gavazzi assume liability for recommendations that appear or are implied in the following description The information in this document is not considered binding on any product w...

Page 4: ...e related national legislation please note that WEEE cannot be disposed of as municipal waste and such waste must be collected and disposed of separately the public or private waste collection systems...

Page 5: ...more solid state relays are needed in a system multiple BUS chains can be utilised Each BUS chain connects to another BUS chain in a line topology via the NRG controllers of the respective BUS chains...

Page 6: ...ation on the functions of each variant refer to Section 6 Through the internal BUS the main controller can read measurement parameters and diagnostics information related to the RG N and its load The...

Page 7: ...the main controller via the 2xRJ45 shielded communication ports The connection between the NRG controller and the solid state relays is through the internal bus cables Each RG N is equipped with 2x mi...

Page 8: ...ny network topology If more than 32 solid state relays are required in an application multiple bus chains can be utilised These can be configured in a line or star topology as deemed fit for the appli...

Page 9: ...tions can be looped from one RG CM N to another since all the loads have the same return path Figure 5 Loads connected between phases Reference connection Ref should always follow the return path of t...

Page 10: ...on on the bus In case of an RG N replacement or any changes to the NRG bus chain the RG Ns have to be re addressed Follow the procedure below Figure 8 to re address the RG Ns on the NRG bus chain manu...

Page 11: ...il must be conductive and grounded Shielded Cat 5e cables fitted with an outer metallic shell should be used The shell should be connected to the wire screen of the cable Figure 9 Metal din clip on NR...

Page 12: ...file from https gavazziautomation com images PIM OTHERSTUFF ESI ESI_NRGC ECAT zip and relocate it in the TwinCAT default directory C TwinCAT 3 1 Config Io EtherCAT 4 2 Integrating the NRG in TwinCAT L...

Page 13: ...LO GAVAZZI LTD V1 0 NRG EtherCAT User Manual 2022 CARLO GAVAZZI LTD EN Find the NRGC ECAT in the EtherCAT device list under Carlo Gavazzi Ltd NRG Controller with EtherCAT Figure 13 Find the NRGC ECAT...

Page 14: ...maximum of 32 RG N solid state relays can be connected to 1 NRGC ECAT In the Slots tab populate the modules depending on which variant of the RG N solid state relays will be installed in the relevant...

Page 15: ...meters can be assigned or re assigned via a service data object Check Communications section for further information If start up parameters are left blank the values saved internally in the RG Ns will...

Page 16: ...mit are mutually exclusive 0 255 0 25 5s Default 0s OFF time to soft start only for RGx1P N 0x2xx2 02 Set the non firing time before soft start is reactivated 0 soft start with occur on power up only...

Page 17: ...voltage used to compensate for deviations in voltage when Voltage Compensation is activated 0 Voltage compensation is disabled 42 600 V reference voltage for voltage compensation 0 42 600V Default 0...

Page 18: ...t 0 Mains loss alarm Flag Bit 1 Load loss SSR open circuit alarm Flag Bit 2 RG N short circuit alarm Flag Bit 3 Voltage out of range alarm Flag Bit 4 Current out of range alarm Flag Bit 5 Frequency ou...

Page 19: ...ble error Flag Bits 12 15 Not used shall be 0 0xF100 0xF100 xx xx RG N position on bus chain in hex Device Status 1 byte Bit 0 Substitute submodule Module type does not match installed RG N variant co...

Page 20: ...eps of 0 01 therefore a value of 1745 17 45A Check Measurements section for more information 0 RG N model dependent UCL value Default RG N model dependent Under current limit UCL 0x2xx1 05 0 RG N mode...

Page 21: ...6 Set the firing mode that the RG N shall use at the output 0 External only for RGx1A N 1 ON OFF 2 Burst 3 Advanced full cycle 4 Distributed full cycle 5 Phase Angle only for RGx1P N RGx1A N default O...

Page 22: ...eading 0 default SSR ON time read only 0x2xx6 03 Holds the accumulated time in hours that the output of the RG N was switched ON 0 default Control level feedback only for RGx1P N read only 0x2xx7 01 H...

Page 23: ...tput OFF and a control level of 100 indicates SSR output ON The advantages of this mode are It is effectively a direct replacement of the A1 A2 i e for existing systems the control algorithm within th...

Page 24: ...ing mode 33 control level Output with Distributed firing mode 50 control level Output with Distributed firing mode 66 control level The advantage of Distributed over Burst is the reduction in thermal...

Page 25: ...d heater applications AFC has the disadvantage of worse harmonics emissions than Burst and also slightly worse than Distributed Phase Angle Firing mode The Phase angle switching mode is available only...

Page 26: ...e mode The soft start will apply the power smoothly to the load over a time period of maximum 25 5s This is settable via the communication system Soft start ramping time setting Soft start with curren...

Page 27: ...ue of 50 means 0 5A and a value of 1747 means 17 47A If a fault occurs in the system such that it is not possible to measure the current this value is 0 This reading is updated every half cycle but is...

Page 28: ...m the initial value at power up the running hours during this power up The reading is updated in steps of 1hour hence a value of 1034 would mean 1034h that the output was ON during its lifetime In the...

Page 29: ...lickering Invalid configuration General Configuration error Possible reason State change commanded by master is impossible due to register or object settings Double Flash Application watchdog timeout...

Page 30: ...rror Description This alarm is issued if the NRG controller detects that the BUS between the NRG controller and the RG Ns is not correctly terminated This can be due to An internal fault in the NRG co...

Page 31: ...Iref registers will be updated by measuring the present current and voltage over a period of time The TEACH command is refuted in case of alarms present on the system If the TEACH is unsuccessful the...

Page 32: ...sued if this condition is present for 10 seconds Though indicated as an alarm condition this alarm has no effect on the function on the RG N and it is up to the user to decide what to do when this ala...

Page 33: ...ceived by the RG N and or replies will not be correctly received by the NRGC and or main controller Diagnose Confirm presence of 24V supply voltage on the NRG Controller US terminals Otherwise replace...

Page 34: ...k it is important to turn it off by pressing again the blue button 2 5 secs otherwise PLC cannot communicate with the NRG bus chain 8 2 Replacing an RG N When an RG N has to be replaced 1 Connect the...

Page 35: ...REF terminal however this will constitute some limitations as listed below 1 The following readings are not available RMS Voltage Real Power and Apparent Power 2 The TEACH operation cannot be executed...

Reviews: