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ELEKTRONIKON MkIV
User Guide : Elektronikon MkIV Modbus
Name
Secr. Class
1102 K/1
Detail
Owner
PC
Edition
01
Modified from
Family
Written By
Design Checked
Product Checked
AII
print date
31/01/03
Compare
Replaces
Approved
Date
Designation
CTE
19/07/2002
9820 3582 02
Document Information
Edition
00
01
..
Date
01/08/2002
14/01/2003
Description
First edition
Second edition
Added exception code Command Refused (07)
Added exception code Reprogrammed Refused (06)
Author
CTE
CTE-PDJ
ii
Preface
This document describes how to implement a Modbus connection to the Elektronikon MkIV compressor controller
network.
iii
Table of Contents
1. The Physical set-up ___________________________________________________________6
1.1
1.2
1.3
LEDs_________________________________________________________________________9
1.4
1.4.1
Power Supply _____________________________________________________________________
1.4.2
LAN connector ____________________________________________________________________
1.4.3
Modbus connection_________________________________________________________________
Pin Assignment Modbus _________________________________________________________________
1.5
1.5.1
1.5.2
1.5.3
1.6
10
10
10
10
2.2
2.3
2.3.1
System Overview __________________________________________________________________
2.3.1.1 General Compressor Condition______________________________________________________
2.3.1.2 Detailed General Compressor Condition ______________________________________________
2.3.2
Inputs & Outputs___________________________________________________________________
2.3.2.1 Analogue Inputs Sensors & Calculated ______________________________________________
2.3.2.2 Registers _______________________________________________________________________
2.3.2.3 Status register Interpretation ______________________________________________________
2.3.2.4 Value register Interpretation ______________________________________________________
2.3.2.4.1 Pressure Input ________________________________________________________________
2.3.2.4.2 Temperature Input_____________________________________________________________
2.3.2.4.3 Vibration Input _______________________________________________________________
2.3.2.4.4 Level Input __________________________________________________________________
2.3.2.4.5 Conductivity Input ____________________________________________________________
2.3.2.4.6 SPM Input___________________________________________________________________
2.3.2.4.7 Current Input_________________________________________________________________
2.3.2.4.8 Speed Input __________________________________________________________________
2.3.2.5 Digital (Voltage free contacts) Inputs _________________________________________________
2.3.2.6 Status register Interpretation ______________________________________________________
2.3.2.7 Value register Interpretation ______________________________________________________
2.3.2.8 Digital (Relays) Output (Not Yet Implemented)_________________________________________
2.3.3
Counters _________________________________________________________________________
2.3.3.1 Compressor Counters _____________________________________________________________
2.3.3.2 Multi Compressor Controller Counters________________________________________________
2.3.4
Special __________________________________________________________________________
2.3.4.1 VSD motor data _________________________________________________________________
2.4
2.4.1
2.4.2
2.4.3
2.5
16
16
17
18
18
18
19
19
19
19
19
19
19
19
20
20
20
20
20
20
21
21
22
23
23
2.5.1
Control Commands _________________________________________________________________ 26
2.5.1.1 Compressor Control Mode Selection _________________________________________________ 26
iv
2.6
2.6.1
2.6.2
2.6.3
2.6.4
28
29
29
30
3.2
3.3
Example______________________________________________________________________31
-6-
Node Id 1
Node Id 2
Node Id 5
Node Id 11
Atlas Copcos
Modbus-Proxy Server
Node Id 1 2 5
Modbus 4 8 10
Customer PLC
Modbus
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.
-7-
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
24Va
Node Id
CAN side
Compr.
Network
-8-
Modbus
Network
System
LED
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 LEDs
The module also has a number of LEDs on type. They are used as follows :
System LED
Blinking : no program loaded or not running
Lit continuously : program running OK
Application LEDs from left to right
1.
not used
2.
not used
3.
4.
5.
6.
7.
not used
8.
not used
9.
not used
-9-
6
1
1
2
3
4
5
6
7
8
9
Function
GND
Reserved
TxD/RxD +
RTS
GND*
+5V*
Reserved
TxD/RxD Reserved
* galvanic isolated
- 10 -
R=120 Ohm
R=120 Ohm
RS-485 ground
1
10x16
- 11 -
R=120 Ohm
RS-485 ground
1
10x16
3
1
7x15
3
7x16
- 12 -
R=120 Ohm
RS-485 ground
1
10x16
R=120 Ohm
- 13 -
- 14 -
T1 T2 T3
ADDRESS
Message body
CRC
T1 T2 T3
- 15 -
Status Information
Stopped (=0) / Running (=1)
Unload (=0)/ Load (=1)
General Warning
General Shutdown-Warning
General Shutdown
General Service
General Start Failure
Emergency Stop
Manual (=0) /Automatic (=1)
Local (=0)/ Remote (=1)
Load/Unload
X
X
X
X
X
X
X
X
X
X
- 16 -
VSD
X
X
X
X
X
X
X
X
X
High Byte
Low Byte
CMS
COM
CS
CCM
GENERAL STATUS
CS_MCC
0
Parameter
General status
CCM
(Compressor Controller Mode)
CMS
(Compressor Mechanical State)
CS
(Compressor State)
Load Unload
CS MCC
(Compressor State)
MCC
CS
(Compressor State)
VSD
Bit
0
1
2
3
4
5
6
7
8
9
10
11
Pre Warning
General Warning
General Shutdown-Warning
General Shutdown
General Service
General Start Failure
Emergency Stop
Manual/Automatic (COS1)
Local/Remote
Timer Not Active/Active
Pre-warning Service Running Hours
Pre-warning Service Accumulated M3
CCM2a
CCM2b
CCM3a
CCM3b
CCM4a
CCM4b
CCM4c (Speed control )
CCM4d (MCC)
No Valid Data
Stopped
Unloaded
Loaded
No Valid Data
A
.
V
No Valid Data
A
D
No Valid Data
A
00
10
01
11
02
12
22
32
00
01
02
04
0
1
.
22
0
1
.
4
0
1
.
22
- 17 -
2.3.2.2 Registers
Sensor Inputs
Function to be used : Read Holding Register (03)
Modbus
register
Information
0001
0002
0003
0004
0005
0006
0109
0110
Analogue Input
Analogue Input
Analogue Input
Analogue Input
Analogue Input
Analogue Input
Analogue Input
Analogue Input
1 Status
1 Value
2 Status
2 Value
3 Status
3 Value
55 Status
55 Value
Information
0111
0112
0113
0114
0115
0116
0117
0118
0119
0120
Calculated Input
Calculated Input
Calculated Input
Calculated Input
Calculated Input
Calculated Input
Calculated Input
Calculated Input
Calculated Input
Calculated Input
1 Status
1 Value
2 Status
2 Value
3 Status
3 Value
4 Status
4 Value
5 Status
5 Value
- 18 -
Bit 7
Input
Set/Not Set
Bit 6
Sensor
Error
Bit 5
Permissive
Start
Bit 4
Service
Bit 3
Shutdown
Bit 2
Shutdown
Warning
Bit 1
Warning
Bit 0
PreWarning
Bit 1
Bit 0
Set
Not Set
Active
Not Active
Active
Not Active
Active
Not Active
Active
Not Active
Active
Not Active
Active
Not Active
Active
Not Active
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 0.1C
For negative values, standard 2-complement notation is used.
Example:
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:
For sensor error the value the value 0xFFFF (hex) is returned.
SPM values cannot be negative
- 19 -
Information
0201
0202
0203
0204
0205
0206
0241
0242
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
1 Status
1 Value
2 Status
2 Value
3 Status
3 Value
21 Status
21 Value
Function
Description
Bit 7
Input
Set/Not Set
Bit 6
Sensor
Error
Bit 5
Permissive
Start
Bit 4
Service
Bit 3
Shutdown
Bit 2
Shutdown
Warning
Bit 1
Warning
Bit 0
PreWarning
Value 1
Value 0
Set
Not Set
Active
Not Active
Active
Not Active
Active
Not Active
Active
Not Active
Not used
Not used
Active
Not Active
Active
Not Active
- 20 -
2.3.3 Counters
2.3.3.1 Compressor Counters
The Elektronikon MkIV supports up to 28 counters (32-bit counters). Each input as 2 x 16bit value register
assigned, to allow a 32-bit value to be read.
Not all types of compressors use all types of counters. The list in this chapter provides an overview of the used
counters / compressor type, and the units that are used
Function to be used : Read Holding Register (03)
Modbus
registers
Information
Units
Load/Unload
VSD
0301+0302
0303+0304
0305+0306
0307+0308
0309+0310
0311+0312
0313+0314
0315+0316
0317+0318
0319+0320
0321+0322
0323+0324
Running Hours
Loaded Hours
Motor Starts
Module Hours
Accumulated Volume
Load cycle
VSD 0-20% RPM
VSD 20-40% RPM
VSD 40-60% RPM
VSD 60-80% RPM
VSD 80-100% RPM
Not yet used
s
s
number
s
1000 m
number
%
%
%
%
%
X
X
X
X
X
-
X
-/X *
X
X
-/X *
X
X
X
X
X
0355+0356
- 21 -
Information
unit
501+502
503+504
505+506
504+507
Compressor 1 counter
Compressor 2 counter
Compressor 3 counter
Compressor 4 counter
s
s
s
s
- 22 -
2.3.4 Special
2.3.4.1 VSD motor data
The Elektronikon MkIV on VSD units contains some important data about the motor speed.This data can be read
over the modbus system.
Function to be used : Read Holding Register (03)
Modbus registers
0801
0802
0803
0804
Information
Required motor speed
Actual motor speed motor 1
Actual motor speed motor 2
Actual motor speed motor 3
unit
rpm
rpm
rpm
rpm
Each register contains a 16-bit value that is directly readable as the equivalent rpm.
- 23 -
Modbus
registers
1061
1062
1063
1064
1065
Description
Pressure Band Selection
Loading pressure band 1
Unloading Pressure band 1
Loading pressure band 2
Unloading Pressure band 2
Description
Setpoint Selection
Setpoint 1
Setpoint 2
- 24 -
Modbus
registers
1081
1082
1083
1084
1085
Description
MCC Pressure Band Selection
MCC Loading pressure band 1
MCC Unloading Pressure band 1
MCC Loading pressure band 2
MCC Unloading Pressure band 2
- 25 -
Value to write
1
2
3
Description
Switch from 4a or 4c to 4b
Switch from 4b or 4c to 4a
Switch from 4a or 4b to 4c
Accepted in mode
4a 4c
4b
4a 4b
Note
Mode 4a : remote control of start/stop but pressure control is done by the controller
Mode 4b : remote control of start/stop and pressure control is done from remote (Supervisory control) (also for
VSD setpoint control)
Mode 4c : remote control of start/stop with external speed (only vsd) speed control)
2004
Value to write
1
2
3
4
5
6
7
1
2
Command
Start
Stop
Load
Unload
MCC Start System
MCC Stop System
MCC Local
Reset Shutdown
Reset Start Failures
- 26 -
Accepted in mode
4a / 4b
4a / 4b
4a / 4b
4b ( in 4a = Manual unload )
4a / 4d
4d
4d
In all Modes
In all Modes
Description
External Setpoint
External Speed
Description
Reset Initial Settings
- 27 -
Example ( Hex)
04
03
00
00
00
02
C4 5E
Response
Field Name
Device Id Nr
Function
Byte Count
Data register 0001
Data register 0002
CRC
Example ( Hex)
04
03
04
00 80 Status
1D 15 ( = Value : 7505 mbar )
DF CA
Example ( Hex)
22
03
00
C8
00
02
42 46
Response
Field Name
Device Id Nr
Function
Byte Count
Data register 0001
Data register 0002
CRC
Example ( Hex)
22
03
04
00 88 Status (Set , Shutdown)
00 00 ( Input Open )
68 DB
- 28 -
Example ( Hex)
01
06
07
D0
00
01
Response
Field Name
Slave address
Function
Register Address High
Register Address Low
Preset Data High
Preset Data Low
CRC
Example ( Hex)
01
06
07
D0
00
01
Example ( Hex)
01
01
00
00
00
08
3D CC
Response
Field Name
Slave address
Function
Byte Count
Data Coils 1 to 8
CRC
Example ( Hex)
01
01
01
00 ( Coils 1 to 8 are = 0 )
51 88
- 29 -
Example ( Hex)
04
08
00
00
A5
37
Response
Field Name
Device Id Nr
Function
Starting Address High
Starting Address Low
Number of points High
Number of points Low
CRC
Example ( Hex)
04
08
00
00
A5
37
- 30 -
3. Exception Responses
3.1 Function Code Data Field
In a normal response, the slave echoes the function code of the orginal query.
In an exception response 80hex is added to the function code.
At the same time an exception code is added in the Data Field.
Name
Illegal Function
02
03
06
Reprogramming Refused
07
Command Refused
08
09
Illegal Command
Meaning
The function code received in the query is not
an allowable action for the slave.
The data address received in the query is not an
allowable address for the slave
A value contained in the query data field is not
an allowable value for the slave
Command Refused because previous command
was not yet executed
Command Refused because previous command
was not yet executed
Check communication cable between MKIV and
Combox-S .
An unknown command is being sent
3.3 Example
Example: read from Analogue input 1, Status and Value
Query
Field Name
Slave address
Function
Starting Address High
Starting Address Low
Number of points High
Number of points Low
CRC
Example ( Hex)
01
09 ( Wrong function, should be 03 )
00
00
00
02
5C 0A
Response
Field Name
Slave address
Function
Exception Code
CRC
Example ( Hex)
01
89 ( Exception reply )
01 ( Illegal Function in query )
86 50
- 31 -