Yokogawa Modbus Communication Training

K-Share on Modbus Mapping
Overview of Modbus
mapping and database
handling
Nanda Kumar T V
GDC-I
29-Dec 22,
| Document Number | March 23, 2016 |

© Yokogawa Electric Corporation
1
Agenda
1. Overview of Subsystem
2. Subsystem Architecture
3. Centum VP Modbus Communication Cards
4. Configuration of ALR121 and ALE111 Card
5. Modbus Device and Address.

2
Subsystem Overview
◼ Subsystem: A System that can Monitor and Control

a section of the Plant & communicate with a
Master system like DCS.
◼ Subsystem communication : communication
performed by a DCS to send and receive data from
a subsystem.
◼ DCS is always the communication master and
Subsystem is always the slave

3
Subsystem Overview
◼ Why subsystem? Why can’t we achieve the same

function in the DCS?
1. Some applications required very fast scan time for control action. Some
PLC has got fast scan time compared to DCS. So such application shall be
configured outside the DCS as a Package and interfaced with the DCS for
operation and control from the same Control room.
Ex. Compressor Control
2. Some application can be able to configure in the DCS. But we may not the
achieve the quality and safety in mechanical equipment, assured and
guaranteed output from the application. A subsystem Package can
provide guaranteed and assured output.
Ex: Steam Turbine control, VMS, TGS.
3. Some subsystems have expertise in data acquisition and transform into
format which other devices can understand .
Ex. Card readers, Bar Code readers.

4
Sub system Architecture

5
Subsystem Architecture

6
4-Wire Modbus configuration RS485
YOKOGAWA TRICONEX TRICONEX
CS3000 SYSTEM TRICON SYSTEM TRICON SYSTEM
ALR121 TB95 TB95

LPT2/RPT2
LPT2/RPT2
11
TX+ RX+
12
TX- RX-
13
RX+ TX+
R1
14
RX- TX-
15
SG SG
FG
R1:Termination Resistor
TX+ Send Data
TX- Send Data
RX+ Receive Data
RX- Receive Data
SG Signal Ground
FG Frame Ground
7
2-Wire Modbus configuration RS232C
YOKOGAWA TRICONEX TRICONEX
CS3000 SYSTEM TRICON SYSTEM TRICON SYSTEM
ALR121 TB95 TB95

LPT2/RPT2
LPT2/RPT2
TX+ 12 RX-
RX+ 14 TX-
TX- 11 RX+
RX- TX+
13
SG SG
15
FG
R1:Termination Resistor
TX+ Send Data
TX- Send Data
RX+ Receive Data
RX- Receive Data
SG Signal Ground
FG Frame Ground
8
Centum VP Modbus
Communication cards

9
Modbus Communication Cards
FCS can communicate with a subsystem by using Modbus RTU protocol (RS-422/
RS-485) via ALR121 communication module that can be installed on Field Control
Unit, ESB Bus Node Unit and Optical ESB Bus Node Unit.
FCS can communicate with a subsystem by using Ethernet TCP/IP protocol via
ALE111 communication module that can be installed on Field Control Unit, ESB
Bus Node Unit and Optical ESB Bus Node Unit.

10
FCS Communication capacity for Modbus TCP
Sr. No Item Max Amount Remark

(For A2FV50D)
1 No of Communication modules Max 32 [16 pairs] per FCS
2 No. of Communication I/O data Max 8000 words / FCS 1 word = 16 bits
3 Amount of data those can be Max 1000 words / Module ALE111
communicated with one
module
4 No. of Communication ports / 1 port
Module
5 No of Subsystem for Max 30 Subsystems Total number of TCP
communication
6 No. of Words per transmission Max 125 Words (AI/O)
Max 8 Words (DI/O)
7 No of Communication Max 128 definitions /
definitions Module

11
Modbus Device and Address

12
➢ The Modbus PLC internal data are called devices.
• Bit device : This refers to data where each bit has a meaning. An internal relay
is equivalent to a bit device.
• Word device : This refers to data where a word unit (1 word = 16 bits) contains
the meaning. A holding register is equivalent to a word device.
➢ MODBUS Communication area on the subsystem is organized mainly into :
➢ INPUT COIL AREA (00000 – 09999)

➢ INPUT RELAY AREA (10000 – 19999)
➢ INPUT REGISTER AREA (30001 – 39999)
➢ HOLDING REGISTER AREA (40001 -49999)

13
➢ Modbus Protocol Function Codes, which are supported by Centum VP.
➢ MODBUS PLC, addresses have the following structure
<Function code> + <device type> + <address of the device>
➢ Modbus function code details:

14
Function Code
A:
Read: Read a packet of data designated on the Communication I/O Builder in
word units.
Write: Write a packet of data designated on the Communication I/O Builder.
With readback.
B:
Read: Read a packet of data designated on the Communication I/O Builder in
word
units.
Write: Only write the changed single bit device or single word device to the
subsystem. With readback.
Readback function:
When there is read back, FCS reads the status of the devices designated in the
Communication I/O Builder back, then compare them with those stored in the
I/O image of FCS. The communication packet to write to the designated devices
of Modbus PLC is sent when discrepancy is detected.

15
Datatype
Data Type contains the following options. The data types can be
selected vary with the subsystem used.
Input (16-Bit Signed)

Input (32-Bit Signed)
Input (16-Bit Unsigned)
Input (32-Bit Unsigned)
Input (32-Bit Floating)
Output (16-Bit Signed)
Output (32-Bit Signed)
Output (16-Bit Unsigned)
Output (32-Bit Unsigned)
Output (32-Bit Floating)
Input (Discrete)
Output (Discrete)

16
Configuration of ALR121 and
ALE111 Card

17
Subsystem Configuration -Modbus
Communication Module ALR 121 configuration :
Select serial
communication
Select
Communication
module
Select for
Redundant card
YOKOGAWA INDIA LIMITED Page.18

Select Modbus

Select Baud rate
Transmission request
Select Parity bit
Select stop bit

Data set ready
Reception carrier
detection
Connection method of
the ALR121 (2-
wire/4-wire). All items are

explained in the next
slide.

Communication Module ALR 121 Set items :
➢ Communication Error Process set items on communication card
➢ Response Timeout :
• This item sets the time for detecting no response from the Subsystem.
• The time is set in units of seconds.
• The recommended setting is 4.
➢ Number of Retries Upon Response Timeout :
• This item sets the number of retries performed when a communication
error occurs.
➢ Interval of Connection Retries :
• This item sets the time interval between checking for communication
recovery with the station that has generated a communication error.
• The time interval is set in units of seconds.
➢ Inter-Character Time-Out Value :
• This item specifies the time for monitoring the interval between
characters during reception.
• An error occurs if the set time is exceeded.
• The time is set in units of ms.

Communication Module ALE 111 configuration :

Communication Module ALE 111 configuration :

Modbus I/O mapping :
➢ To communicate with subsystems, first assign a storage area for
communication data for each subsystem connected.

➢ Setting Items on Communication I/O Builder
➢ Element- With respect to the address of the subsystem data buffer, the
element numbers are displayed on Communication I/O Builder. The
element number is not for set, only for display
➢ Buffer- This sets the buffer for the communicated data. This is a required
setting item of the Communication I/O Builder

➢ Program Name- Set the unit number, slot number and MODBUS as program
name in the following format:
• Kt-n-sProgramName
• K : FIO identifier
• t : System number (Specify 1.)
• n : Node number
• s : Slot number
• Program Name : MODBUS
➢ Size -This item sets the data size (data length) from the head address set
in “Device & Address.”
• For MODBUS PLC the setting ranges are limited as follows
• For analog input and analog output: 1 to 124 words
• For discrete input and discrete output: 1 to 8 words
➢ Station-This sets the station number of the MODBUS PLC. The station
numbers that can be set are 1 to 255.

➢ Device & Address - Set the head address of MODBUS PLC data
➢ Data Type -This sets data type of the subsystem data
➢ Reverse- This sets whether or not to make the bit arrangement in FCS in
reverse order of the subsystem data. The following settings can be
selected:
• Bits [ Yes/ No]
➢ Scan- Set whether to read the communication I/O Analog data into the
communication I/O data buffer at the beginning of high-speed scan of the
FCS.
• The default value Scan setting is 1 Second.
➢ Service Comment -A text comment can be set.
➢ Label- The name of the function block I/O terminal can be set as a user-
defined label.
Modbus I/O map Generation :
➢ Accessing subsystem data varies according to the type of communication
module used

Modbus I/O map Generation :
➢ Correspondence between a %WW element (16-bit data) and %WB
elements (1-bit data)

Scaling :
The Linear Transformation of the analog data (PV) into the form of an integer
data within the specific integer range (Modbus Range).
Why Scaling is required?
To get good resolution in the PV values. (Up to few decimal places)
Note: For Floating data types scaling is not required.

Scaling :
Accessing subsystem analog input data : Data conversion is necessary at DCS for
representation on the engineering scale
• PV(DCS) = PV (Subsystem) × GAIN + BIAS
TAG_1
PVI
IN
%WW0001
Subsystem
[Analog Input]
16 Bit data

➢ The Gain and Bias can be calculated using the formula
Gain =
Bias =
where Rmax = Maximum Instrument Scale Value

Rmin = Minimum Instrument Scale Value
Pmax = Maximum Modbus Range
Pmin = Minimum Modbus Range

Modbus communication module status :
➢ The ALR121 are serial communication modules that are installed to the
node unit for ESB bus is 10 pole terminal block for two RS-422 or RS-485
ports (5 poles/port)
➢ LED Display Indications:
●STATUS :
This LED turns on (green colour) when the self diagnosis has been
completed normally and the hardware is ready, otherwise it is turned off.
•ACT :
When the module is operating normal, LED is ON (green colour) otherwise
it is turned off.
•DX :
This LED turns on(green colour) when module is configured for dual-
redundant operation.
•SND-1 & 2:
This LED turns on (green colour)during data transmission, otherwise it is
turned off. The status is as per the Communication port basis.
•RCV-1 & 2:
This LED turns on (green colour) during data reception, otherwise it is
turned off. The status is as per the Communication port basis.

Tips for Modbus IO Mapping:

➢ Check for required information in available in the database like
Tag name, analog PV range, Modbus range, Modbus address,
AI/AO/DI/DO, Slave address.
➢ Calculate the number for words including analog and digital
(<1000) for estimating the buffer size and packet data size.
➢ Check for the consecutive address is available, which makes
mapping easier. If the address are not consecutive then we
have to take in care in allocating right WW address.
➢ While allocating the packet data size in the WW builder,
ensure that number of words not crossing 124 for analog and
8 for digital.
➢ Leave some spare words (10-20%) between each packet of
data for future changes.
➢ If all the 16 bits are not used in the discrete input data, it is
better not configure the unused bits in WB builder, as the WB
builder can accommodate only 1000 tags.

Tips for establishing the communication:

➢ Check for communication cable pin configuration.
➢ Check for the communication parameters are set properly in
DCS and subsystem side like Baud rate, Parity, 2wire/4wire,
Station no (Slave address), IP address (Ethernet) and
communication Error Process set items.
➢ Appropriate program name has to be selected in the WW
builder for the respective subsystem.
➢ No Mismatch in the Function code, Data type and Modbus
address.
➢ Ensure spare words, which are allocated between each packet
of data is not more which may cause error in communication.

Error Codes:
➢ A3B0 : No Response
➢ A3B1 : Inappropriate station number
➢ A3B5 : Too many communication processing points
➢ A3B6 : Write to a read-only device occurred
➢ A3C3 : Function code error
➢ A3C2 : Address error

Thank you

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K-Share on Modbus Mapping

| Document Number | March 23, 2016 |

| Document Number | March 23, 2016 |

◼ Subsystem: A System that can Monitor and Control

| Document Number | March 23, 2016 |

◼ Why subsystem? Why can’t we achieve the same

| Document Number | March 23, 2016 |

| Document Number | March 23, 2016 |

| Document Number | March 23, 2016 |

ALR121 TB95 TB95

ALR121 TB95 TB95

| Document Number | March 23, 2016 |

| Document Number | March 23, 2016 |

Sr. No Item Max Amount Remark

| Document Number | March 23, 2016 |

| Document Number | March 23, 2016 |

➢ The Modbus PLC internal data are called devices.

➢ MODBUS Communication area on the subsystem is organized mainly into :

➢ INPUT COIL AREA (00000 – 09999)

| Document Number | March 23, 2016 |

➢ Modbus function code details:

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| Document Number | March 23, 2016 |

Input (16-Bit Signed)

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| Document Number | March 23, 2016 |

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Select Baud rate

Select stop bit

wire/4-wire). All items are

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Why Scaling is required?

To get good resolution in the PV values. (Up to few decimal places)

Note: For Floating data types scaling is not required.

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➢ The Gain and Bias can be calculated using the formula

where Rmax = Maximum Instrument Scale Value

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Tips for Modbus IO Mapping:

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Tips for establishing the communication:

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| Document Number | March 23, 2016 |

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