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Atlas Copco Airpower NV ELEKTRONIKON MkIV User Guide : Elektronikon MkIV Modbus Name User Guide : Elektronikon MkIV Modbus Secr. Class 1102 K/1 Detail PC Owner AII Edition 01 Modified from : print date 31/01/03 Family Written By CTE Compare Replaces Designation Design Checked Product Checked Approved Date 19/07/2002 9820 3582 02 User Guide : Elektronikon MkIV Modbus ii Document Information Edition Date Description Author 00 01/08/2002 First edition CTE 01 14/01/2003 Second edition CTE-PDJ Added exception code Command Refused (07) .. Added exception code Reprogrammed Refused (06) User Guide : Elektronikon MkIV Modbus iii Preface This document describes how to implement a Modbus connection to the Elektronikon MkIV compressor controller network. User Guide : Elektronikon MkIV Modbus iv Table of Contents 1. The Physical set-up ___________________________________________________________6 1.1 Modbus & the Network __________________________________________________________6 1.2 The Module (Combox-S) _________________________________________________________8 1.3 LED’s_________________________________________________________________________9 1.4 Connector lay-out______________________________________________________________10 1.4.1 Power Supply _____________________________________________________________________ 10 1.4.2 LAN connector ____________________________________________________________________ 10 1.4.3 Modbus connection_________________________________________________________________ 10 Pin Assignment Modbus _________________________________________________________________ 10 1.5 RS485 connections _____________________________________________________________11 1.5.1 Modbus with MKIV________________________________________________________________ 11 1.5.2 Modbus with MKIV and MKIII_______________________________________________________ 12 1.5.3 Modbus with MKIV and Other Equipment ______________________________________________ 13 1.6 Software downloading __________________________________________________________14 2. Modbus protocol implementation_______________________________________________15 2.1 Supported modbus specification _________________________________________________15 2.2 Supported Modbus functions ____________________________________________________15 2.3 Modbus registers and coils for Data Reading _______________________________________16 2.3.1 System Overview __________________________________________________________________ 16 2.3.1.1 General Compressor Condition______________________________________________________ 16 2.3.1.2 Detailed General Compressor Condition ______________________________________________ 17 2.3.2 Inputs & Outputs___________________________________________________________________ 18 2.3.2.1 Analogue Inputs – Sensors & Calculated ______________________________________________ 18 2.3.2.2 Registers _______________________________________________________________________ 18 2.3.2.3 “Status” register Interpretation ______________________________________________________ 19 2.3.2.4 “Value” register Interpretation ______________________________________________________ 19 2.3.2.4.1 Pressure Input ________________________________________________________________ 19 2.3.2.4.2 Temperature Input_____________________________________________________________ 19 2.3.2.4.3 Vibration Input _______________________________________________________________ 19 2.3.2.4.4 Level Input __________________________________________________________________ 19 2.3.2.4.5 Conductivity Input ____________________________________________________________ 19 2.3.2.4.6 SPM Input___________________________________________________________________ 19 2.3.2.4.7 Current Input_________________________________________________________________ 20 2.3.2.4.8 Speed Input __________________________________________________________________ 20 2.3.2.5 Digital (Voltage free contacts) Inputs _________________________________________________ 20 2.3.2.6 “Status” register Interpretation ______________________________________________________ 20 2.3.2.7 “Value” register Interpretation ______________________________________________________ 20 2.3.2.8 Digital (Relays) Output (Not Yet Implemented)_________________________________________ 20 2.3.3 Counters _________________________________________________________________________ 21 2.3.3.1 Compressor Counters _____________________________________________________________ 21 2.3.3.2 Multi Compressor Controller Counters________________________________________________ 22 2.3.4 Special __________________________________________________________________________ 23 2.3.4.1 VSD motor data _________________________________________________________________ 23 2.4 Modbus registers and coils for parameters change __________________________________24 2.4.1 Load/Unload Pressure Band change ____________________________________________________ 24 2.4.2 VSD Setpoint change _______________________________________________________________ 24 2.4.3 MCC Pressure Band change __________________________________________________________ 25 2.5 Modbus registers and coils for remote control ______________________________________26 2.5.1 Control Commands _________________________________________________________________ 26 2.5.1.1 Compressor Control Mode Selection _________________________________________________ 26 User Guide : Elektronikon MkIV Modbus v 2.5.1.2 Compressor Commands ___________________________________________________________ 26 2.5.2 VSD – external setpoint/speed control __________________________________________________ 27 2.5.3 Reset Initial Settings (Analogue , Digital , Counter Inputs) __________________________________ 27 2.6 Communication examples _______________________________________________________28 2.6.1 Analogue - Digital Inputs ____________________________________________________________ 28 2.6.2 Commands description ______________________________________________________________ 29 2.6.3 Present System Status _______________________________________________________________ 29 2.6.4 Loopback Test ____________________________________________________________________ 30 3. Exception Responses _________________________________________________________31 3.1 Function Code – Data Field______________________________________________________31 3.2 Exception Codes _______________________________________________________________31 3.3 Example______________________________________________________________________31 User Guide : Elektronikon MkIV Modbus - 6 - 1. The Physical set-up 1.1 Modbus & the Network In the Elektronikon MkIV system all compressors in an installation can be connected by a data and/or control network. This is done according the Compressor Network Cabling Instruction (9820 3585 00). This instruction explains what connectors and cables should be used to interconnect the different compressors/controllers in the network. Basically this is a CAN-based local network. In order to setup a modbus connection to one or several of the compressors in this network, a special module as to be inserted in this network. This module will then behave as a modbus-proxy that allows access to all compressors in the network, whereby each compressor has its own modbus address (proxy concept). User Guide : Elektronikon MkIV Modbus - 7 - In this drawing the proxy is used to access the compressors with Node Id 1,2 and 5, by using the modbus addresses 4,8 and 10. (This proxy-conversion table has to be set with proper tools). The Node Id the Proxy itself if 11 on the CAN side. Modbus Customer PLC Atlas Copco’s Modbus-Proxy Server Node Id 1 Node Id 2 Node Id 5 Node Id 1 2 5 Modbus 4 8 10 Node Id 11 User Guide : Elektronikon MkIV Modbus - 8 - 1.2 The Module (Combox-S) For the modbus connection a so-called Combox-S module has to be used (AC n° 19000711 41). This is a general purpose serial communication module. By downloading the correct software in it, it will perform the modbus proxy function. Because this is a general purpose module, not all connections/switches will be used for this connection. For modbus the following will be used � 10x14 : � to connect a 24Vac supply � 2 top address switches (LAN) � to set the Atlas Copco Lan address (= CAN side address !!), the Fieldbus switches are NOT used, because the Modbus addresses (proxy) are defined by software and programmed with an external (PC) software. � 10x1: � to connect to the compressor network (CAN) � 10x16 : � to connect the RS485 modbus line The other connectors/switches are NOT used for this application System LED Application LED’s 24Va Node Id CAN side Compr. Network Modbus Network User Guide : Elektronikon MkIV Modbus The module itself can be mounted on a DIN-rail inside one of the compressor cubicles, or on a separate location. Before installation check the available power of the 24Vac transformer, if connecting to an already supplied transformer inside a cubicle.. 1.3 LED’s The module also has a number of LED’s on type. They are used as follows : System LED Blinking : no program loaded or not running Lit continuously : program running OK Application LED’s from left to right 1. not used 2. not used 3. CAN receive (Combox receives CAN message) 4. CAN transmit (Combox transmits CAN message) 5. Modbus receive (Combox receives Modbus message) 6. Modbus transmit (Combox transmits Modbus message) 7. not used 8. not used 9. not used 10. Modbus Mode 11. not used - 9 - User Guide : Elektronikon MkIV Modbus - 10 - 1.4 Connector lay-out 1.4.1 Power Supply This is a two pole Wago (type …) connector. Power supply is 24Vac, 10VA 1.4.2 LAN connector Connect here the cable of the compressor network, according AC instruction : Compressor Network Cabling Instruction (9820 3585 00). 1.4.3 Modbus connection The module supports the RS485A variant of modbus, with the following pin-layout and termination requirements as specified Pin Assignment Modbus Sub-D 9 pole female Pin Function 1 GND 2 Reserved 3 TxD/RxD + 4 RTS 5 GND* 6 +5V* 7 Reserved 8 TxD/RxD - 9 Reserved * galvanic isolated 1 6 User Guide : Elektronikon MkIV Modbus - 11 - 1.5 RS485 connections 1.5.1 Modbus with MKIV Elektronikon MkIV, 1900 0711 41 10x16 8 3R=120 Ohm Customer, Modbus Master 1 R S-485 ground R=120 Ohm User Guide : Elektronikon MkIV Modbus - 12 - 1.5.2 Modbus with MKIV and MKIII Elektronikon MkIV, 1900 0711 41 8 3 10x16 7x15 7x16 8 3 8 3R=120 Ohm R=120 Ohm Elektronikon MkIII, 1900 0701 82 Customer, Modbus Master 1 1 R S-485 ground User Guide : Elektronikon MkIV Modbus - 13 - 1.5.3 Modbus with MKIV and Other Equipment Elektronikon MkIV, 1900 0711 41 10x16 8 3R=120 Ohm R=120 Ohm Other Modbus equipment Customer, Modbus Master 1 R S-485 ground User Guide : Elektronikon MkIV Modbus - 14 - 1.6 Software downloading Before the module can be used for a modbus connection the appropriate software must be loaded. This can be done by AC Service personal with the AC Field Downloading Program (FDP). The programs/settings are available in a the Communication Devices database 1900 0712 51 (filename 1900071251_xxxx.DS4, xxxx = edition) With this program it is also possible to program the modbus/CAN address conversions. After programming , put power off/on of the combox-S to activate the modbusaddresses. Before powering the Combox –S module , check all cables. User Guide : Elektronikon MkIV Modbus - 15 - 2. Modbus protocol implementation 2.1 Supported modbus specification The Combox-S when downloaded with the proper modbus software supports the following modbus- variant � RTU mode of transmission � Coding system : binary � Mode : half duplex ( RS485 ) � Number of start bits : 1 � Number of data bits : 8 � Baudrate : 300,600,1200,2400,4800,9600*,19200*,38400 � Parity control : even*,odd*,none * � Number of stop bits : 1 or 2 � Error checking : CRC-16 * These parameters are defined during downloading of the controller. Frame synchronization in the RTU mode is done by simulating a synchronous message. The slave device monitors the elapsed time between receipt of characters. If three character time elapsed without a new character, then the device assumes that the message is completed and the next byte will be the address The message frame format is following : 2.2 Supported Modbus functions The Elektronikon MkIV modbus implemenentation supports the following message type , depending on the type of data involved (see details below) Function 01 : read coil status Function 03 : read holding register Function 06 : preset single register Function 08 : loop back test T1 T2 T3 ADDRESS Message body CRC T1 T2 T3 User Guide : Elektronikon MkIV Modbus - 16 - 2.3 Modbus registers and coils for Data Reading 2.3.1 System Overview 2.3.1.1 General Compressor Condition Function to be used : Read Coil Status (01) Modbus Coil Status Information Load/Unload VSD 0001 Stopped (=0) / Running (=1) X X 0002 Unload (=0)/ Load (=1) X 0003 General Warning X X 0004 General Shutdown-Warning X X 0005 General Shutdown X X 0006 General Service X X 0007 General Start Failure X X 0008 Emergency Stop X X 0009 Manual (=0) /Automatic (=1) X X 0010 Local (=0)/ Remote (=1) X X User Guide : Elektronikon MkIV Modbus - 17 - 2.3.1.2 Detailed General Compressor Condition Function to be used : Read Holding Register (03) Modbus register High Byte Low Byte 0401 CMS COM 0402 CS CCM 0403 GENERAL STATUS 0404 CS_MCC 0 Parameter Bit General status 0 Pre – Warning 1 General Warning 2 General Shutdown-Warning 3 General Shutdown 4 General Service 5 General Start Failure 6 Emergency Stop 7 Manual/Automatic (COS1) 8 Local/Remote 9 Timer Not Active/Active 10 Pre-warning Service Running Hours 11 Pre-warning Service Accumulated M3 CCM (Compressor Controller Mode) CCM2a CCM2b CCM3a CCM3b CCM4a CCM4b CCM4c (Speed control ) CCM4d (MCC) 00 10 01 11 02 12 22 32 CMS (Compressor Mechanical State) No Valid Data Stopped Unloaded Loaded 00 01 02 04 CS (Compressor State) Load Unload No Valid Data A ……. V 0 1 …. 22 CS MCC (Compressor State) MCC No Valid Data A …… D 0 1 …. 4 CS (Compressor State) VSD No Valid Data A …… V 0 1 …. 22 Very Important Note !!!!!. When CS is 0 or CMS is 0 ALL data for that compressor is not Valid. � Check Cables . When there is bad communication , only the detailed general compressor condition will be set to 0. User Guide : Elektronikon MkIV Modbus - 18 - 2.3.2 Inputs & Outputs 2.3.2.1 Analogue Inputs – Sensors & Calculated The Elektronikon MkIV supports up to 55 analogue sensor inputs and 5 additional analogue calculated (virtual) inputs. Each input has a ‘value’ and a ‘status’ register assigned. The contents of these registers depend on the actual type of sensor that is connected. This can be different for every type of compressor. E.g. standard compressors may have 1 to 4 pressure inputs, 1 to 10 temperature inputs, up to 7 SPM inputs,… Also, features and options may increment the number of sensors that are actually installed on your compressor. Before using the modbus system it is therefore required to find out what sensors are really connected to your compressors. This can e.g. be done with the FDP program. This program has a function that lists the sensors + modbus registers for a selected compressor type (including features and options). Once the list of sensors is known, the contents of the registers can be interpreted as described below. 2.3.2.2 Registers Sensor Inputs Function to be used : Read Holding Register (03) Modbus register Information 0001 Analogue Input 1 – Status 0002 Analogue Input 1 – Value 0003 Analogue Input 2 – Status 0004 Analogue Input 2 – Value 0005 Analogue Input 3 – Status 0006 Analogue Input 3 – Value … … 0109 Analogue Input 55 – Status 0110 Analogue Input 55 – Value Calculated (virtual) Inputs Function to be used : Read Holding Register (03) Modbus register Information 0111 Calculated Input 1 – Status 0112 Calculated Input 1 – Value 0113 Calculated Input 2 – Status 0114 Calculated Input 2 – Value 0115 Calculated Input 3 – Status 0116 Calculated Input 3 – Value 0117 Calculated Input 4 – Status 0118 Calculated Input 4 – Value 0119 Calculated Input 5 – Status 0120 Calculated Input 5 – Value User Guide : Elektronikon MkIV Modbus - 19 - 2.3.2.3 “Status” register Interpretation High order byte = 00 Low order byte = Input Status The Input Status must be interpreted as Binary data (bit coded). Each part ( bit ) of the data ( byte ) is indicating a specific item that applies on the Input function. In the following table, an overview is given of all bits together with the corresponding meaning and interpretation. Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Function Description Input Set/Not Set Sensor Error Permissive Start Service Shutdown Shutdown Warning Warning Pre- Warning Bit “1” Set Active Active Active Active Active Active Active Bit “0” Not Set Not Active Not Active Not Active Not Active Not Active Not Active Not Active 2.3.2.4 “Value” register Interpretation This depends on the type of inputs. 2.3.2.4.1 Pressure Input The Pressure Input Value is a 2 byte integer, and contains the actual reading in mbar (0.001 bar) For negative values, standard 2-complement notation is used. Example: Value = 7040 decimal or 0x1B80 hexadecimal = 7.040 bar. Value = -1000 decimal (2-complement) or 0xFC18 = -1.000 bar For sensor error the value the value 32767 or 7FFF (hex) is returned. On some high pressure compressors (with working pressures above 30 bar) a special Pressure Input can be defined that returns data in cBar (0.01 bar) in stead of mBar. 2.3.2.4.2 Temperature Input The Temperature Input Value is a 2 byte integer, and contains the actual reading in 0.1°C For negative values, standard 2-complement notation is used. Example: Value = 855 decimal or 0x0357 hexadecimal = 85.5 °C Value = -250 decimal (2-complement) or 0xFF06 = -25.0 °C For sensor error the value the value 32767 or 7FFF (hex) is returned. 2.3.2.4.3 Vibration Input tbd 2.3.2.4.4 Level Input tbd 2.3.2.4.5 Conductivity Input tbd 2.3.2.4.6 SPM Input The SPM Input Value is a 2 byte register that must be seen as 2 x 1 byte. � Byte 1 : carpet value (in dB) � Byte 2 : peak value (in dB) Example: Value = 0x1120 = > carpet value = 0x11, peak value = 0x20 For sensor error the value the value 0xFFFF (hex) is returned. SPM values cannot be negative User Guide : Elektronikon MkIV Modbus - 20 - 2.3.2.4.7 Current Input tbd 2.3.2.4.8 Speed Input tbd 2.3.2.5 Digital (Voltage free contacts) Inputs The Elektronikon MkIV supports up to 18 digital (voltage free) inputs. Each input has a ‘value’ and a ‘status’ register assigned. The contents of these registers is for digital inputs always the same, if the input is used. Before using the modbus system it is therefore required to find out what inputs are used on your compressors. This can e.g. be done with the FDP program. This program has a function that lists the digital inputs + modbus registers for a selected compressor type (including features and options). Once the list of inputs is known, the contents of the registers can be interpreted as described below. Function to be used : Read Holding Register (03) Modbus register Information 0201 Digital Input 1 – Status 0202 Digital Input 1 – Value 0203 Digital Input 2 – Status 0204 Digital Input 2 – Value 0205 Digital Input 3 – Status 0206 Digital Input 3 – Value … … 0241 Digital Input 21 – Status 0242 Digital Input 21 – Value 2.3.2.6 “Status” register Interpretation High order byte = 00 Low order byte = Input Status The Input Status must be interpreted as Binary data. Each part ( bit ) of the data ( byte ) is indicating a specific item th