User guide

1. General Information

Mk5 Gateway Module as Modbus Interface

Document Number : 2946 2070 00

Document Edition : 01
Concerning : Mk5 Gateway and Unit Controller connected by a CAN network
Preliminary Operations : –
Safety Instructions : General
Persons Required : 1
Special Tools : –
Consumables : –

2. Document Overview
This document covers the following subjects:
1. General Information ..................................................................................................................................................... 1
2. Document Overview ..................................................................................................................................................... 1
3. Safety first .................................................................................................................................................................... 3
4. Copyright Notice........................................................................................................................................................... 4
5. Document Information and History ............................................................................................................................... 4
6. Safety Precautions ....................................................................................................................................................... 5
Safety icons ............................................................................................................................................................. 5
Safety precautions during installation ...................................................................................................................... 5
Safety precautions during operation ........................................................................................................................ 6
Safety precautions during maintenance or repair .................................................................................................... 7
7. Preface......................................................................................................................................................................... 8
8. Physical Set-up ............................................................................................................................................................ 8
Modbus in the network ............................................................................................................................................. 8
Gateway module ...................................................................................................................................................... 8
Modbus pin-layout ................................................................................................................................................... 9
RS485 external cabling in a network ....................................................................................................................... 9
9. Software installation and configuration......................................................................................................................... 9
Display menu folder structure ................................................................................................................................ 10
Main screen folder [ ] ...................................................................................................................................... 10
General Settings folder [ GE ]............................................................................................................................ 10
Compressors folder [ CP ] ................................................................................................................................. 14
10. Gateway Display Description ..................................................................................................................................... 15
Icons ...................................................................................................................................................................... 15
LEDs ...................................................................................................................................................................... 15
Keyboard ............................................................................................................................................................... 15

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 Passwords / Security Access Codes ..................................................................................................................... 16
11. Modbus Protocol Implementation ............................................................................................................................... 17
Supported Modbus specification ............................................................................................................................ 17
Supported Modbus functions ................................................................................................................................. 17
Function code - data field ...................................................................................................................................... 17
Details and examples of the protocol ..................................................................................................................... 18
11.4.1 Function 1 - read coil............................................................................................................................................. 18
11.4.2 Function 3 - read holding register.......................................................................................................................... 19
11.4.2 Function 6 – write single register........................................................................................................................... 20
11.4.3 Function 8 – loopback test .................................................................................................................................... 21
Modbus Address mapping ..................................................................................................................................... 21
11.5.1 Mark 5 generation of controllers ........................................................................................................................ 21
11.5.2 Central Controllers – new generation ................................................................................................................ 22
11.5.3 Mark IV generation of controllers ....................................................................................................................... 22
11.5.4 Small CD dryers equipped with a ‘Timer Card’ .................................................................................................. 22
11.5.5 Central Controllers – older generation ............................................................................................................... 22
Trouble Shooting ................................................................................................................................................... 22
11.6.1 Introduction ........................................................................................................................................................... 22
11.6.2 PC Tools............................................................................................................................................................ 23
12. Functional explanations on external control ............................................................................................................... 24
Machines ............................................................................................................................................................... 24
12.1.1 Fix Speed compressor equipped with Mk5 unit controller ..................................................................................... 24
12.1.2 Variable Speed Drive (VSD) compressor equipped with Mk5 unit controller......................................................... 24
12.1.3 Fix Speed compressor equipped with MkIV unit controller ................................................................................ 24
12.1.4 Variable Speed Drive (VSD) compressor equipped with MkIV unit controller.................................................... 25
12.1.5 ZH Turbo compressors ...................................................................................................................................... 25
12.1.6 ZB Turbo compressors ...................................................................................................................................... 25
12.1.7 High Pressure compressors/boosters from Crépelle - both fix speed and VSD ................................................ 26
12.1.8 Dryers ................................................................................................................................................................ 26
12.1.9 Vacuum Pumps ................................................................................................................................................. 26
12.1.10 Gas generators ............................................................................................................................................. 26
12.1.11 Energy Recovery Kit ..................................................................................................................................... 26
Central Controllers ................................................................................................................................................. 26
12.2.1 ESi and ES6 equipped with Mk5 unit controller ................................................................................................. 26
12.2.2 ESi and ES6 of the MkIV generation ................................................................................................................. 27
12.2.3 Central Controllers: Old types ES8 and ES130 ................................................................................................. 27
12.2.4 Central Controllers: New types ES16 and ES360 ............................................................................................. 27

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3. Safety first

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4. Copyright Notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

5. Document Information and History

Edition Date Description Author

00 31/03/2017 First edition of renewed Modbus user manual CTS

01 08/06/2017 First official release CTS

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6. Safety Precautions

Safety icons

Danger for life

Warning

Important note

Safety precautions during installation

All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance
of the normal caution and care required for installation, operation, maintenance and repair, even if not
expressly stated, will be disclaimed by the manufacturer.

General precautions
The operator must employ safe working practices and observe all related work safety requirements and regulations.
If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.
Installation, operation, maintenance and repair work must only be performed by authorized, trained, specialized personnel.
Before carrying out any maintenance, repair work, adjustment or any other non-routine checks, stop the device. In addition,
the power isolating switch must be opened and locked.

Precautions during installation

Place the device where the ambient air is as cool and clean as possible.
During installation or any other intervention on one of the connected machines, the machine must be stopped, de-energized
and the isolating switch opened and locked before any maintenance or repair. As a further safeguard, persons
switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or
working on the machine. To this end, a suitable notice shall be affixed to the start equipment.
The electrical connections must correspond to the local codes. The device must be earthed and protected against short
circuits by fuses in all phases. A lockable power isolating switch must be installed near the device.
For machines controlled by a central control system, a sign stating "This machine may start without warning" must be affixed
near the instrument panel.
In multiple compressor systems, manual valves must be installed to isolate each compressor. Non return valves (check
valves) must not be relied upon for isolating pressure systems.
Never remove or tamper with the safety devices.

Also consult following safety precautions: Safety precautions during operation and Safety
precautions during maintenance or repair.
These precautions apply to electrical devices.
For precautions applying to the connected equipment consult the relevant instruction book.
Some precautions are general and cover several machine types and equipment; hence some
statements may not apply to your device.

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 Safety precautions during operation
General precautions
1. The operator must employ safe working practices and observe all related local work safety requirements and
regulations.
If any of the following statements does not comply with local legislation, the stricter of the two shall apply.
Installation, operation, maintenance and repair work must only be performed by authorized, trained, specialized personnel.
Before carrying out any maintenance, repair work, adjustment or any other non-routine checks, stop the device. In addition,
the power isolating switch must be opened and locked.

Precautions during operation

1. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one
checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment.
Never operate the device in the presence of flammable or toxic fumes, vapors or particles.
Never operate the machine below or in excess of its limit ratings.
Keep all bodywork doors and panels closed during operation. The doors may be opened for short periods only, e.g. to carry
out routine checks. Wear ear protectors when opening a door if applicable.
People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A) shall wear ear
protectors.
Periodically check that:
 All guards are in place and securely fastened
 All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
 There are no leaks
 All fasteners are tight
 All electrical leads are secure and in good order
 Safety valves and other pressure-relief devices are not obstructed by dirt or paint
 Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of wear or
abuse
Never remove or tamper with the safety devices.

Also consult following safety precautions: Safety precautions during installation and Safety
precautions during maintenance or repair.
These precautions apply to electrical devices.
For precautions applying to the connected equipment consult the relevant instruction book.
Some precautions are general and cover several machine types and equipment; hence some
statements may not apply to your device.

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 Safety precautions during maintenance or repair
General precautions
1. The operator must employ safe working practices and observe all related local work safety requirements and
regulations.
If any of the following statements does not comply with local legislation, the stricter of the two shall apply.
Installation, operation, maintenance and repair work must only be performed by authorized, trained, specialized personnel.
Before carrying out any maintenance, repair work, adjustment or any other non-routine checks, stop the device. In addition,
the power isolating switch must be opened and locked.

Precautions during maintenance or repair

1. Use only the correct tools for maintenance and repair work.
2. Use only genuine spare parts.
3. A warning sign bearing a legend such as "work in progress; do not start" shall be attached to the starting equipment,
including all remote start equipment.
4. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one
checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment.
5. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic vapors
of cleaning liquids.
6. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and exposed
openings with a clean cloth, paper or tape.
7. Never use a light source with open flame for inspecting the interior of the device.
8. All regulating and safety devices shall be maintained with due care to ensure that they function properly. They may not
be put out of action.
9. Before clearing the device for use after maintenance or repair, check that operating pressures, temperatures and time
settings are correct. Check that all control and shut-down devices are fitted and that they function correctly.
10. Never use caustic solvents which can damage materials of the air net.

Also consult following safety precautions: Safety precautions during installation and Safety
precautions during operation.
These precautions apply to electrical devices.
For precautions applying to the connected equipment consult the relevant instruction book.
Some precautions are general and cover several machine types and equipment; hence some
statements may not apply to your device.

Units and/or used parts should be disposed of in an environmentally friendly and safe manner
and in line with the local recommendations and legislation.

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7. Preface
This document describes how to implement a Modbus connection to the Elektronikon MkIV and/or Elektronikon Mk5
compressor controller network.
The 0x notation is used in this document for hexadecimal values: e.g. 0x12 corresponds with decimal value 18.

8. Physical Set-up

Modbus in the network

In the Elektronikon 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 (2946 1361 00). This instruction explains the connectors and
cables to use to interconnect the different compressors/controllers in the network. Basically this is a CAN-based network.
In order to set up a Modbus connection to one or several of the compressors in this network, a special module has to be
inserted in this network.
This will behave as a Modbus proxy that allows access to all compressors in the network, whereby each compressor has its
own Modbus address (proxy concept).
The module will as well behave as a bridge to access the data stored in the CAN node’s Object Dictionary. In order to work
correctly, this bridge module has to be assigned a slave node ID. From the master’s point of view, this bridge acts as a way
to access information of the CANBUS network.

Elektronikon Elektronikon Elektronikon

MkIV Mk5 Mk5
CAN: 1 CAN: 2 CAN: 3

CAN

Modbus:
CAN 1 > Node 5
CAN 2 > Node 6
CAN 3 > Node 15
Modbus

Mk5 Gateway
Modbus
Master

Gateway module
For the Modbus connection a so-called “Mk5 Gateway” is used. This is a general purpose serial communication module. By
downloading the correct software, it will perform the proxy and/or bridge function.
The following connections are used:
6x36 24Vac power supply
6x20 Atlas Copco compressor network (CAN)
6x25 ethernet connection to PC for downloading/commissioning the application
6x22 RS485 Modbus line
6x37 Profibus line
6x38 connection is not used by this application.

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 Modbus pin-layout
For the Modbus connection, the Gateway module supports RS485A, with the following pin-layout as specified.

9 pin Female Sub-D Connector

Pin Function

1 GND
2 Reserved
3 TxD / RxD+
4 Reserved
5 Reserved
6 Reserved
7 Reserved
8 TxD / RxD-
9 Reserved

RS485 external cabling in a network

There is an internal resistor of 120 Ohm between RS485A and RS485B signal lines, so it is not advised to connect two
gateways on a multi-drop RS485 connection.
As per standard RS485 installation guidelines a 120 Ohm resistor is connected across the signal pair at the DCS end and
we normally have another 120 Ohm resistor connected across the signal pair at the last device on the cable. Most RS485
devices have either no resistor or a switchable resistor, so the end user can manipulate its network. Now both the Mk5
Gateways have internally a 120 Ohm resistor; this causes too high load and reduced signal level.
Note: When the customer removes this internal pcb-mounted resistor it is on his responsibility (no more warranty).

9. Software installation and configuration

Before the module can be used for a Modbus connection, the correct software application and settings must be downloaded.
This has to be done by the AC Service technician using the AC Speci5 PC tool.
Once the software has been installed, configuration can be performed by qualified Atlas Copco technician using AC Modi5
or AC Speci5 PC tool.
It is the responsibility of Atlas Copco to generate the Address Mapping documents, available for each individual machine.
These documents must be delivered together with this user manual. The mappings list all supported registers and their
interpretation.

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 Display menu folder structure
Once the module is downloaded, the default settings are found on the module. It is now important to set up the module
correctly according to the need of the customer.
This can be done by the user interface on the Mk5 Gateway (as explained below), but it is much easier to do this by the PC
commissioning tools (done by the Atlas Copco Technician on request of the customer).
The display menu structure is built up as follows:

Each folder has one or more subfolders which can be accessed using the Enter key on the keyboard. Exiting a folder can be
performed using the Cancel key. Browsing through the different folders is done by pressing the Left and Right button.
Once a setting is reached in a specific folder, the current settings value will be displayed. By pressing Cancel the current
menu will be exited. Pressing Enter however will allow the user to alter the settings (the value will start blinking) by clicking
the Up or Down button. At this point the user will be able to undo the current settings change by clicking Cancel. In this
case the current settings value will be shown again. However, by clicking Enter the settings value will be stored and the
module will behave accordingly.

Main screen folder [ ]

The Main screen folder has no subfolders and is only used to display general information. The module will always return to
this folder in case no button is pressed over a certain period.
The following icons can be displayed:

Icon Description

On: CAN engine stopped

Running: CAN engine running

Off: Modbus engine stopped

On: Modbus engine running

Off: Profibus engine stopped

On: Profibus engine running

General Settings folder [ GE ]

The General Settings folder consists of 4 subfolders which will be explained in the next paragraphs.

9.1.2.1 Communication Folder [ Co ]

The Communication folder basically offers the possibility to edit the parameters that are used to properly communicate over
the CAN channel (with the attached Elektronikon modules on the CAN network), the RS485 Modbus channel and the
Profibus channel.
It also offers the possibility to set/alter the Ethernet settings. Be aware that this is protected by security codes.

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Modbus Engine
The Modbus Engine can be started/stopped here.
NOTE: In case the Modbus Engine is active, the settings for Modbus Baud rate, Modbus Parity and Modbus Stop bits are not accessible.
Modbus Baud rate
Below table lists the possible Modbus baud rate, indicated as follows:

Display value Baud rate

0 9600 bps
1 19200 bps
2 38400 bps
3 57600 bps
4 115200 bps
5 230400 bps
6 460800 bps

Modbus Parity
Below table lists the possible Modbus parities, indicated as follows:

Display value Parity

0 None
1 Even
2 Odd

Modbus Stop bits

Select the number of used stop bits (1 or 2).

Profibus Engine
The Profibus Engine can be started/stopped here.
NOTE: This manual is about Modbus, so the Profibus engine should be stopped (although technically both engines can be active at the
same time without influencing the functionality and timing). Details about how to setup the Profibus can be found in another user manual.

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Ethernet Engine
The Ethernet Engine can be started/stopped here.
NOTE: the Ethernet port can only be used by PC tools from Atlas Copco, the customer cannot use this connection
Ethernet IP Address
The Ethernet IP Address can be set/altered here.
Ethernet Network Mask
The Ethernet Network Mask can be set/altered here.
Ethernet Gateway
The Ethernet Gateway can be set/altered here.

CAN Engine
The CAN Engine can be started/stopped here.
NOTE: the setup of the CAN channel must be done by Atlas Copco Technician. In case the CAN Engine is active, the setting for CAN
Channel is not accessible.
CAN Channel
Below table lists the possible CAN channels, indicated as follows:

Display value Channel

1 Primary
2 Secondary

9.1.2.2 CAN folder [ CA ]

The CAN folder contains the settings that are used by the internal CAN Engine and contains the following subfolders:

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Every functional data block can be set to low of high priority; disabling functional blocks will not significantly speed up the
CAN update cycle while only present blocks will be scanned (according to the initial creation of the internal structure). Be
aware that only a few blocks can be set to high priority, else the high priority will become slower than normal priority due to
the way of implementation. By default the optimal setting for most cases is implemented.

Display value Priority

0 Off
1 Normal
2 High

9.1.2.3 Password Setting [ PW ]

The customer has the possibility to create a password for even more protection on top of the Atlas Copco security codes to
prevent accidental parameter changes. The different password folders offer the possibility to enable/disable and alter the
customer password.

9.1.2.4 Program Information [ PI ]

The Program Information folder shows information that is associated with the current application.

Program Number
The Program Number folder shows the program number that is associated with the current application.
Program Revision
The Program Revision folder shows the program revision number that is associated with the current application.
Operating System
The Operating System folder shows the operating system number that is associated with the current application.
Boot Software
The Boot Software folder shows the boot software number that is associated with the current application.

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 Compressors folder [ CP ]
The Compressors folder contains 31 subfolders ([CP01] to [CP31]) each containing 2 subfolders, describing the compressor
parameters.
NOTE: Channel 31 should not be used in a CAN network.

The following icons can be shown:

Icon Description

Blinking: Compressor related menu : machine is in CAN Error

On: machine is defined/enabled and is able to request data

Blinking: machine is defined/enabled and is able to request settings

9.1.3.1 CAN Status folder [ MA01 ]

This parameter defines whether the controller is read-out over CAN.
NOTE: In case the CAN Status is set to disabled for a certain controller, no data will be retrieved and hence the respective registers will be 0
in the Modbus communication.

9.1.3.2 Modbus Node folder [ MA02 ]

This parameter defines the controller slave address for the Modbus communication.

9.1.3.3 Information folder [ Info ]

In this folder, respectively the following data is shown expressed in seconds. Use the Up/Down keys to select.
 The cycle time of the CAN engine (this is the time that the application requires to update the data in the Mk5
Gateway internal buffer) for ‘Normal Priority’ data blocks
 The cycle time of the CAN engine (this is the time that the application requires to update the data in the Mk5
Gateway internal buffer) for ‘High Priority’ data blocks
 The time it takes to answer on a Modbus request for this CAN node ID

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10. Gateway Display Description

Icons

Icon Description

Blinking: Compressor related menu : machine is in CAN Error

On: CAN engine stopped

Running: CAN engine running

Off: Modbus engine stopped

On: Modbus engine running

Off: Profibus engine stopped

On: Profibus engine running

On: machine is defined/enabled and is able to request data

Blinking: machine is defined/enabled and is able to request settings

LEDs

LED Description

On: Gateway module is powered on

NOTE: No other LEDs are used during the operation of the application.

Keyboard

Key Description

Up
Edit settings parameters
Down
Left
Browse through the different menus
Right

← Enter to select / accept

ₓ Cancel to cancel / ignore

‫׀‬ Start is NOT used in this application

‫ס‬ Stop is NOT used in this application

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 Passwords / Security Access Codes
Please consult the table below to know the type of password that has to be entered in a given menu.
Customer Passwords and/or Security Access Codes can be identified by their appearance on the display.

Blinking key(s) Non blinking key(s) Description

1 digit 3 dashes Enter the Customer Password

3 dashes 1 digit Enter the applicable Security Access Code
1 digit 3 digits Enter the new Customer Password
3 digits 1 digit Confirm the new Customer Password

Access codes are to be requested from Atlas Copco.

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11. Modbus Protocol Implementation

Supported Modbus specification

The Gateway module supports the following Modbus-variant:
 Mode of transmission : RTU
 Coding system : binary
 Mode : RS485
 Number of start bits: 1
 Number of data bits: 8
 Baud rate: 9600, 19200, 38400, 57600, 115200, 230400, 460800
 Parity control: even, odd, none
 Number of stop bits: 1, 2
 Error checking: CRC16
Frame synchronization in the RTU mode is done by simulating a synchronous message. The slave device monitors the
elapsed time between receipts of characters. If three character time (referred to as Tx) 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 as follows:

T1 T2 T3 Address Message Body CRC T1 T2 T3

Supported Modbus functions

The Elektronikon Mk5 Gateway - Modbus supports the following message type, depending on the type of data involved (see
details below).
 Function 01 : read coil register
 Function 03 : read holding register
 Function 06 : pre-set single register
 Function 08 : Loopback test

Function code - data field

In a normal response, the slave echoes the function code of the original query.
In an exception response, 0x80 is added to the original function code; Also an exception code is added in the Data Field.
Exception codes

Code Name Description

01 Illegal function The function code received in the query is not an

allowable action for the slave
02 Illegal Data Address The data address received in the query is not an
allowable address for the slave
03 Illegal Data Value A value contained in the query data field is not an
allowable value for the slave
06 Reprogramming Refused Command refused because previous command was
not yet executed
07 Command Refused Command refused because previous command was
not yet executed
08 Data Not Available Check Communication cable between Elektronikon
and the Gateway module
09 Illegal Command An unknown command is being sent
0A Invalid CRC Checksum The CRC16 checksum received is incorrect
0B Write Refused Parameter change refused

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Example of Illegal Data Address: if the slave device is asked for a parameter which it cannot provide, the slave device
answers with the error code Illegal Data Address. As an example we read the speed from a fixed speed compressor.
Request (function ID 03) of one data record - register 0x0320 (decimal 800 corresponds with register 801 in Modicon
notation) from Modbus slave 05, crc represents the check sum.
Indicated values are hexadecimal: the feedback does not contain an answer and the function ID is replaced by error code 80
and exception code 03
Request 0x 05 03 03 20 00 01 crc
Answer 0x 05 83 03 02 crc

Details and examples of the protocol

11.4.1 Function 1 - read coil

This function provides digital information value 0 or 1 are returned for the available coils. The Atlas Copco controllers only
provide 10 coils indicating the status of the machine.
Modbus Message Format (all values given in hexadecimal values)
Request 0x 05 01 00 00 00 0A
Answer 0x 05 01 02 00 02
Request (function ID 01) of 10 coils starting from coil 00 00 from Modbus slave 05. The answer mirrors the Modbus slave 05
and function ID 01 (check here for error codes) and adds the number of bytes 02 that are returned and the actual bytes
containing the coil data: 00 02
Below you can find another example:

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 11.4.2 Function 3 - read holding register
This function provides all available data from our machines according to a certain address mapping (see next chapter).
Every Modbus register contains 2 bytes of data.
Modbus Message Format (all values given in hexadecimal values)
Request 0x 05 03 03 E8 00 02
Answer 0x 05 03 04 00 01 EB 23
Request (function ID 03) of 02 registers starting from register 1001 (Modicon notation 41001 – always detract 1 and convert
to hexadecimal in the actual protocol, 1000 = 0x03E8) 03 E8 from Modbus slave 05. The answer mirrors the Modbus slave
05 and function ID 03 (check here for error codes) and adds the number of bytes 04 that are returned and the actual content
of the requested registers: 00 01 EB 23 (first 2 bytes for first register)
Some explanations of interpretation of the data:
 Definition of a Modbus register: 2 bytes; first is the HIGH byte and the second one is the LOW byte; each byte has
8 bits, the least significant bit is bit0 the most significant bit is bit7
 For analog inputs: 2 byte values are in technical units (indicated in column 'Unit') in 'Signed Integer' format
 For analog and digital inputs next to the register containing the actual value also a register is available that
indicates some status bits (marked in blue in the address mappings – see next chapter).
 When a sensor is in error, the value 32767 (Hexadecimal 7FFF) is returned and also the error bit is set in the
corresponding status register
 Counter values are found in two registers: e.g. 301 (answer is B4 and B3) & 302 (answer is B2 and B1): total value
is a Double WORD B4 B3 B2 B1 e.g. hexadecimal 00 2C 93 45 = 2921285 seconds
 For counter values 2 registers are used e.g. example given above registers 1001 and 1002 contain 00 01 EB 23;
convert 0x0001EB23 to decimal = 125731 seconds divided by 3600  34 hours

Register Higher Byte Lower Byte

1001 B4 B3

1002 B2 B1

 To calculate the % of speed ranges for VSD compressors: the register contain values in seconds, these must be
compared with the total running hours (RH) counter. The following formula converts seconds value into % (as
shown on the display of the controller): value [s] * 100 / RH [s]
Example:
Running hours [s] 65 [s]
01– 20 [%] 41 [s]
21 – 40 [%] 13 [s] 13 * 100 / 65 = 20 %
41 – 60 [%] 03 [s] 3 * 100 / 65 = 4.61  5%
61 – 80 [%] 01 [s] 1 * 100 / 65 = 1.53  2 %
81 – 100 [%] 07 [s] 7 * 100 / 65 = 10.76  11 %
Total = 38 %
Calculate 01 – 20 [%] 100 – 38 = 62 %

 To interpret counters of type RTC = number of seconds passed since 1 January 1970 (Epoch Time)

Example: 54E3 29B5 Hex = 1424173493 decimal => 45 years + 58 days + 11 hours + 44 minutes + 53 seconds 
17 February 2015 11:53
Tip: you can use the epoch convertor from internet: www.epochconverter.com/

 The interpretation of 1 register for a SPM reading: 2 bytes must be interpreted as 2 separate bytes
Data from MkIV Master controller:
High Byte contains carpet (average) value [db] value from 0 – 80
Low Byte contains peak (maximum) value [db] value from 0 – 80
Example: value 0x1120  carpet: 0x11 =17 [db]; peak: 0x20 = 32 [db]
Data from Mk5 Master controller:
High Byte contains peak (maximum) value [db] value from 0 – 80
Low Byte contains carpet (average) value [db] value from 0 – 80
Example: value 0x2011  carpet: 0x11 =17 [db]; peak: 0x20 = 32 [db]
A sensor error can be detected by the sensor error status bit; in this case the value returned = 0 and not 7FFF. The
SPM value cannot be negative. The status but ‘valid measurement’ indicates that a valid measurement value is
returned, this bit is not reset. The protocol does not provide a Time Stamp of the last valid measurement as can be

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 seen on the Mk5 display. So the valid measurement can be an old value. The Mk5 unit controller only measures
SPM when the machine is running loaded.
Bit 8 ‘valid measurement’ = 0 when no valid measurement has been taken (from power on until running stable
speed in loaded condition without a sensor error)
Bit 8 ‘valid measurement’ = 1 when a valid measurement is saved in memory. You should check the time stamp to
see how old this measurement is. It can be that the machine is stopped / unloaded, or even has a sensor error, but
still the protocol provides the last valid measurement that was saved. (Time stamp can be seen on the display of
the controller).

Below you can find an example for function 03 and how to interpret the data

11.4.2 Function 6 – write single register

This function allows to change some parameters and to control the machine externally. The address mapping (see next
chapter) shows all available data and control possibilities to change using the Modbus protocol. The supported protocol does
not allow to write more than one register at the time.

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Modbus Message Format (all values given in hexadecimal values)
Write request 0x 05 06 03 5C 00 02
Answer 0x 05 06 03 5C 00 02
Write request (function ID 06) of the value 00 02 into register 861 (Modicon notation 40861 – always detract 1 and convert to
hexadecimal in the actual protocol, 860 = 0x035C) 03 5C for Modbus slave 05. The answer just mirrors the write request:
Modbus slave 05, function ID 06 (check here for error codes) register 03 5C and value 00 02. This example changes the
active Pressure Band to Pressure Band #2 for a fix speed compressor.
Another example:

When using the write commands, it is important to understand the external control functionality supported by the different
types of controllers (hardware and software). Consult the chapter ‘Functional explanations on external control’

11.4.3 Function 8 – loopback test

Modbus function code 08 provides a test for checking the communication system between a master and a slave device.
The normal response is to return the Query Data.

Modbus Address mapping

11.5.1 Mark 5 generation of controllers

The part numbers of the Mk5 unit controller usually starts with 5200.
When the machine is equipped with an Elektronikon® of Mark 5 generation an Atlas Copco technician can generate the
complete address mapping using the PC Tool Speci5. An excel sheet with a ‘general’ mapping is available as “Modbus
address mapping for Mk5.xls”. When the mapping is created by Speci5, it contains the complete and correct mapping
including more details about inputs, outputs and counters.

11.5.1.4 High Pressure Machines from Crépelle

The only difference is that for some pressure readings the technical unit is [centibar] iso [millibar] to allow values higher than
32 bar fitting in 2 bytes signed integer.

11.5.1.6 Gas generator

Typically more types of analog inputs are provided (other technical units e.g. Flow [l/min] and concentration [ppm]) and also
analog outputs – currents from 4 to 20 mA.

11.5.1.7 Vacuum Pump

Typically some pressure values are indicated in absolute pressure iso relative pressure: e.g. unit type mbar (a)

11.5.1.8 Energy Recovery Unit Kit

Typically some applications dependent ‘internal’ data is available; this includes calculated savings (units kWh, currency,
Real Time Clock)

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11.5.2 Central Controllers – new generation
The ES6 is based on the Mk5 generation of controllers, so the detailed address mapping can be generated by an Atlas
Copco technician using the Speci5 PC tool similar as in previous chapter. An excel sheet with a ‘general’ mapping is
available as “Modbus address mapping for ES6 - Mk5.xls”
The ES16 and ES360 central controllers can also be configured to allow external Modbus communication via the Mk5
Gateway. The Atlas Copco technical ES specialist can generate the address mapping using the ES Tuner tool. This contains
all details about the available data and commands. An excel sheet with a ‘general’ mapping is available as “Modbus
address mapping for ES16-360.xls”.

11.5.3 Mark IV generation of controllers

The part numbers of the Mk5 unit controller usually begins with 1900.
When the machine is equipped with an Elektronikon® of Mark IV generation, an Atlas Copco technician can generate part of
the mapping using the PC Tool FDP, this only contains the list of registers dynamically generated based on the actual
inputs, counters and special alarms. In the excel sheets below, you can find next to the ‘general’ inputs, counter registers
also the registers for parameters and the available commands. The registers are different based on the type of machine. The
same remark for the high pressure values as given above for Mk5 High Pressure Machines from Crépelle. An excel sheet
with a ‘general’ mapping is available as “Modbus address mapping for MkIV.xls”.

11.5.4 Small CD dryers equipped with a ‘Timer Card’

A fixed address mapping is available for this type of controller. An excel sheet with this mapping is available as “Modbus
address mapping for CD dryer TimerCard ed9b”. Contact the Atlas Copco technician to check if your dryer is equipped
with the correct edition of this TimerCard and to set all dip-switched correct to allow external communication.

11.5.5 Central Controllers – older generation

3 different types of older central controllers exist: ES6 (based on MkIV generation of unit controllers), ES8 and ES130.
The address mapping for these devices are documented in the old Modbus user manual for the ComBox-S; this manual can
be requested from Atlas Copco.

Trouble Shooting

11.6.1 Introduction
Some easy tips to check the functionality of the Mk5 Gateway:
About the CAN communication: check the icon on the display in section CP
 Select the CAN node (CPxx) and check if ‘running loaded’-icon is steady shown
 If this is not, check the commissioning parameters, the CAN cabling and the CAN settings of the connected unit
controller.
 If icon is OK you can press enter and press arrow right till you see info; press enter and down arrows and check the
update cycle of the data and response time on last Modbus request on this CAN channel.
About the Modbus communication, if no valid answers are received:
 Check the RS485 cable (pin layout is described in earlier chapter)
 Check the RS485 communication settings: Baud rate, parity, stop bit
o For the Mk5 Gateway this can be done on the display (see chapter about the display)
o Contact the Atlas Copco Technician to set/modify the settings of the Mk5 Gateway
 Check the data sent to the gateway (see examples above)
Next chapter describes some tools running on a PC that can help to trouble shoot the communication, The Atlas Copco
technical specialist should be able to demonstrate the proper functionality of the Gateway.

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11.6.2 PC Tools
It is not always clear to customers or external consultants how to read/write using our Modbus protocol as supported by the
Mk5 Gateway based on this manual. Therefore a PC running some test program can be used to demonstrate the proper
functioning of the Mk5 Gateway according to its specification.
Required Hardware: While a PC does not have a RS485 port, we need a USB to RS485 conversion; this can be easily found
on the market. Atlas Copco advises the converters from Easy Sync. It can even be ordered from Atlas Copco (part number
3001 5022 00), this includes the required correct cables to connect the interface to connection 6x22 of the Gateway.

11.6.2.1 ModScan
This is freeware software from Win-Tech. Versions are available for all kind of Windows Operating Systems. More info can
be found on internet.
http://www.win-tech.com/html/modscan32.htm
After installing the drivers for the USB2RS485 interface (to be downloaded from internet)
http://www.easysync-ltd.com/product/542/es-u-3001-m-.html
It is important to check on your PC - Control Panel – Device Manager – Ports and verify the virtual COM port assigned to the
USB2RS485 interface.
Make a connection with correct baud rate/parity/stop bits and see the response on Coil and Holding registers.

11.6.2.2 Atlas Copco Test tools

Special developed Modbus Test Programs (MBT) are available for the Atlas Copco Technician, these programs are typically
designed to show the status, pressures and temperature of our machines and even allow to generate Start/Stop commands.

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12. Functional explanations on external control

Machines
Stand-alone machines connected by a CAN network to an Mk5 Gateway can be controlled by using the Modbus protocol if
certain conditions are met. The possibilities are based on the type of unit controller installed on the machine and also the
type of machine. This chapter gives some explanations.

12.1.1 Fix Speed compressor equipped with Mk5 unit controller

 It is not possible to overwrite the local Pressure Band (Un) Load levels. For full external control we advise to install
an ES system from Atlas Copco. Contact Atlas Copco for more details.
 It is however possible to switch from the Active Band (PB #01 or PB #02) that is used by the local regulation
algorithm by remote commands. This is possible both in local as LAN control mode.
 The controller will only accept other remote commands when in LAN control mode. This mode must be activated
using the display/keyboard of the controller.
 In LAN a control mode the controller uses its local pressure (Un) Load levels compared to the measured
compressor outlet pressure to start/stop and load/unload the machine.
After a START or LOAD command the controller goes to Automatic control mode
After a STOP command the controller reverts to Manual Stopped mode
After an UNLOAD command the controller goes to Manual Unload mode
 In LAN b control mode the controller will Start, Stop and (Un) Load based on external commands only (all
machine safety functions will still be active). So the compressor will not (Un) Load when the compressor outlet
pressure passes the pressure band levels.
 When the controller switches from 4b to 4a control mode (after a command or after elapsing the CAN
communication timeout), the controller will regulate automatically again, so based on the outlet pressure and the
local pressure band settings, so the machine can Start, Stop, Load or Unload.

12.1.2 Variable Speed Drive (VSD) compressor equipped with Mk5 unit controller
 Only the speed of the main motor can be read, so it is not possible to read the speed of FAN or Dryer motor.
 Two speed values can be read for the main motor: the actual running speed and the speed that is requested from
the unit controller towards the converter.
 It is not possible to overwrite the local Pressure Set Point level. In normal mode it is not possible to steer the speed
externally by Modbus commands. For full external control we advise to install an ES system from Atlas Copco.
Contact Atlas Copco for more details.
 It is however possible to switch from the Active Set Point (Set Point #01 or Set Point #02) that is used by the local
regulation algorithm by remote commands. This is possible both in local as LAN control mode.
 The controller will only accept other remote commands when in LAN control mode. This mode must be activated
using the display/keyboard of the controller.
 In LAN a control mode the controller still uses its local Set Point level versus the outlet pressure to control the
speed (PID loop) in automatic control mode.
After a START command the controller goes to Automatic control mode
After a STOP command the controller reverts to Manual Stopped mode
Only for VSD having a stable ‘unload status’ the UNLOAD command will steer the machine to manual Unload
running mode.
 LAN b control mode is not supported by the VSD.

12.1.3 Fix Speed compressor equipped with MkIV unit controller

 It is possible to overwrite the local Pressure Band (Un) Load levels. This can be done in the different control modes:
Local, Remote and LAN control mode.
o So next to switching from the Active Band (PB #01 or PB #02) that is used by the local regulation
algorithm, it is also possible to change the (Un) Load levels of both pressure bands.
 The controller will only accept other remote commands when in LAN control mode. This mode must be activated
using the display/keyboard of the controller.

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  In LAN a control mode the controller uses its local pressure (Un) Load levels compared to the measured
compressor outlet pressure to start/stop and load/unload the machine.
After a START or LOAD command the controller goes to Automatic control mode
After a STOP command the controller reverts to Manual Stopped mode
After an UNLOAD command the controller goes to Manual Unload mode
 In LAN b control mode the controller will Start, Stop and (Un) Load based on external commands only (all
machine safety functions will still be active). So the compressor will not (Un) Load when the compressor outlet
pressure passes the pressure band levels.
 When the controller switches from 4b to 4a control mode (after a command or after elapsing the CAN
communication timeout), the controller will regulate automatically again, so based on the outlet pressure and the
local pressure band settings, so the machine can Start, Stop, Load or Unload.

12.1.4 Variable Speed Drive (VSD) compressor equipped with MkIV unit controller
 Only the speed of the main motor can be read, so it is not possible to read the speed of FAN or Dryer motor.
 Two speed values can be read for the main motor: the actual running speed and the speed that is requested from
the unit controller towards the converter.
 It is possible to overwrite the local pressure Set Point. This can be done in the different control modes: Local,
Remote and LAN control mode.
o So next to switching from the Active Set Point (Set Point #01 or Set Point #02) that is used in local control
mode, it is also possible to change the Set Point pressure levels.
 The controller will only accept other remote commands when in LAN control mode. This mode must be activated
using the display/keyboard of the controller.
 In LAN a control mode the controller still uses its local Set Point level versus the outlet pressure to control the
speed (PID loop) in automatic control mode.
After a START command the controller goes to Automatic control mode
After a STOP command the controller reverts to Manual Stopped mode
Only for VSD having a stable ‘unload status’ the UNLOAD command will steer the machine to manual Unload
running mode.
 LAN b control mode is not supported by the VSD.

12.1.5 ZH Turbo compressors

 This type of machine has some specific data related to its control algorithm. Analog outputs that control the Inlet
Guide Vane (IGV) and the Blow Off Valve (BOV). The status of these valves can be read in percentages.
 About the external control possibilities on the Pressure Set Point used by the Turbo regulation algorithm, it is similar
as for the VSD explained above. For the MkIV unit controllers the value of the Set Point and the load and unload
offset levels can be overwritten, this is not possible for the Mk5 unit controller. For full external control we advise to
install an ES system from Atlas Copco. Contact Atlas Copco for more details.
 There are more external commands available (only when the unit controller is in LAN control mode)
o Start / Load  Turbo will use its regulation algorithms to regulate to the active Set Point
o Stop  Machine will go to manually stopped condition
o Unload  BOV will open and IGV will close
o Minimum Minimum Load  BOV minimum closed and IGV minimum open
o Minimum Load  BOV maximum closed and IGV minimum open
o Full Load  BOV maximum closed and IGV maximum open
 There is no detailed external control possible for the IGV and BOV.

12.1.6 ZB Turbo compressors

 This type of machine has some specific data related to its control algorithm. Analog outputs that control the Water
Circuit Valve (WCV) and the Blow Off Valve (BOV). The status of these valves can be read in percentages.
 About the external control possibilities check the chapters on VSD machines.

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 12.1.7 High Pressure compressors/boosters from Crépelle - both fix speed and VSD
 While this machines deliver high pressurized air, higher than 32 bar (32000 mbar), another type of Pressure unit is
introduced to be able to keep all algorithms working with two byte values. The technical unit for some pressure will
be [cbar] is stead of [mbar], so values can vary from -1 bar to 320 bar; 32767 centibar is the maximal signed integer
value in Hexadecimal format 7FFF)
 These machines can be equipped with controllers of the Mk5 or MkIV generation and exist also in both Fix Speed
and Variable Speed versions. The external control possibilities are exactly the same as for the standard Fix speed
and VSD. Off course be aware of the difference used technical unit for high pressure values.
 About the fix speed Piston Compressors some types have parallel pistons and can be used for delivering half the
flow, this is called the 50 % regulation. So in this case next to the external Unload and Load command also the 50
% Load command exists.

12.1.8 Dryers
 A lot of different types of dryers exist, so the list of measurements, counters, digital outputs and special protections
can vary a lot. Always consult the detailed address mapping generated by the Atlas Copco Technician.
 The external control possibilities are very limited. Only a Start and Stop command is available:
o Start  the unit controller will regulate automatically
o Stop  the unit controller will no longer regulate, the machine is in complete stopped condition

12.1.9 Vacuum Pumps

 This type of machines are launched with the Mk5 unit controller and regulate similar as the standard VSD
machines, the only difference is that in this case the regulation pressure is in absolute pressure [bar (a)] starting
from 0 (absolute vacuum) to 1000 mbar (a) (atmospheric - ambient pressure).
 For the algorithm and external control, check the chapter about MK5 VSD machines.

12.1.10 Gas generators

 This type of machines are launched with the Mk5 unit controller and do not have an advanced regulation algorithm.
Based on the flow the gas filtering can achieve better or worse results. Some specific analog measurements are
introduced, check the generated address mapping for more details.
 About external control, the behavior is similar to a dryer, only the Start and Stop commands are available causing
the switch from ON / OFF machine running condition.

12.1.11 Energy Recovery Kit

 This type of machine is launched with the Mk5 unit controller and has some specific data. This is available in the
“Internal Data” functional block. Check the generated address mapping for more details
 About external control, the behavior is similar to a dryer, only a Start and a Stop command is available that
switches the machine from ON / OFF running condition.

Central Controllers
Atlas Copco has a wide range of Central controllers. These controllers take over the full control of all integrated machines.
These controllers are also connected to the CAN network, in that way the Mk5 Gateway can also provide some data and
even external control via Modbus.

12.2.1 ESi and ES6 equipped with Mk5 unit controller

ESi provides the same functionality as the stand alone ES6 but it is integrated in the unit controller of one machine in the
network called the ES Master.
 The controller will only accept remote commands when in LAN control mode. This mode must be activated using
the display/keyboard of the controller.
 It is possible to select the Active ES regulation band #01 or #02, this can be changed by an external Modbus
command; this command can be given in local or LAN control mode.
 It is not possible to overwrite the local ES Pressure Band (Un) Load levels. Contact Atlas Copco for more details.
 In LAN a control mode the controller still uses its local ES pressure (Un) Load levels to steer the connected ‘slave’
machines.
After an ES START CONTROLLING command the ES will switch to Central Automatic Regulating control mode.

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 After an ES CENTRAL STOP command the ES will stop all connected machines in a controlled way resulting in a de-
pressurized air net. This function can be disabled by a setting in the ES Controller.
After an ES TO LOCAL CONTROL command the controller will switch to ES Local control mode resulting in switching
all connected machines in local control in a controlled way.

12.2.2 ESi and ES6 of the MkIV generation

The behavior is exactly the same as for the version equipped with an MK5 unit controller; only now it is possible to overwrite
the local ES Pressure Band (Un) Load levels. This can be done in the different control modes: Local, remote and LAN
control mode.

12.2.3 Central Controllers: Old types ES8 and ES130

All available registers are mentioned in a fixed address mapping (see previous chapter). It includes all the possibilities for
external control.

12.2.4 Central Controllers: New types ES16 and ES360

The address mapping generated by ES Tuner contains all the details and some explanations for external control. These
controllers do not have a LAN control mode, so external commands are always accepted. Off course in some cases internal
ES conditions must be met else the commands are ignored.
In the analog and calculated data, also measurement points which are ‘aggregated’ can be listed. While there is no time
period reference these values cannot be used (the values are only supported for upload towards SMARTLINK). In the near
future a new release (2.0) will support these value properly. The Atlas Copco Technician will be able to define the time frame
for the accumulated calculated data. By default it will be every 60 seconds, so it is up to the customer to read the value
every minute and do its own accumulation.
Integrating/Isolating a specific machine
 The ES will only control the integrated machines, isolated machine can be manually stopped (e.g. for maintenance)
or run ‘locally’ automatic – based on their own settings
 Writing the value 1 (isolate) or value 2 (integrate) in the register matching with the CAN Node of the connected
machine will change its integration status.
 It is not possible to read the integration status of the connected machines from the ES
 The integration status of connected machines can be read from the individual machines (use other Modbus slave
addresses)
o Read register 702 / low byte; values 0, 1 or 2 indicate “isolated” and values 18, 34 or 50 “integrated”

External controlling the SPS settings

 Switching from SPS set by writing a valid value in register 2005
 Changing the pressure levels of an SPS in different steps
o Before actually changing the levels, all individual levels can be overwritten and afterwards if all conditions
are met (high alarm level > high warning level > Unload level > Set Point level > Load level > low warning
level > low alarm level) the command <apply changes> can be send
o It is recommended to read the SPS levels after changing them to verify if the operation was successful.

Externally changing the central control mode

 by writing another profile value in register 2007
 reading register 1387 gives the actual profile
 check the address mapping for the available profiles
o value 0  Local control mode
o value 2  central ‘energy saving’ control mode
o value 3  central ‘equal running hours’ control mode
o value 4  central ‘flow based’ control mode
o value 252  central control based on defined flow schedule
o value 253  central control based on defined periodical schedule
value 254  central control based on defined week timer schedule

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