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How To … Debug Subsystem Communication

Main types of Subsystem Communication:

Modbus RS 232 – Not used so often, can handle only one station (PLC, device etc)

- Point to point
- Minimum 3 wire connection (transmit, receive, ground)
- DB-25 connector

Modbus RS 485 – Used often, simple implementation, can handle more stations (PLC, device etc)

- Point to Point and Multi Point

- Minimum 2 wire connection
- Optimal 4 wire connection
- Profibus uses RS485 serial communication protocol
- Resistor (120 ohm on Yokogawa side needed)

Modbus TCP/IP - Used often, can involve redundancy issues if servers are used by the 3rd Party Vendors
rather than communication cards.

- Point to Point and Multi Point

- Ethernet Connection
- Easy to configure from the system point of view
o layer 2 switches are optional
o same slave can be pulled from two or more masters (e.g. one ALE111 per FCS)
o connection is physically safe (no terminals used)
Debugging physical connection

RS 232

- Check cable and connector integrity pin by pin (continuity test)

- Check that communication parameters on Yokogawa and 3rd Party are the same
(communication card)

RS 485

- Check cable integrity wire by wire (continuity test)

- Check terminals both at Yokogawa and at 3rd Party Vendor
- Check that communication parameters on Yokogawa and 3rd Party are the same
(communication card)

4 wire single point

4 wire multi point

2 wire single point

2 wire multi point

Modbus TCP/IP

- Check cable integrity

- Check that communication parameters on Yokogawa and 3rd Party are the same
(communication card)
Debugging system connection (common for all connection types)

After physical connection check if we still have no communication we start with the WW
allocation check versus received database together with Modbus specific checks

1. Communication card capacity

2. Modbus Function code reflected in Device&Address

Coils

Holding Registers
Note :

Following table illustrates details on each type of code. Readback option should be turned off if
communication errors or no communication at all appear when outputs (digital or analog) are defined.

3. Bitmap (database allocation)

Note: A new call is needed when each time data type changes:

Check WW allocation (WB allocation has no impact on communication parameters) against received
database and against 3rd party vendor allocation
 4. Online debugging (Process Report)

.PR (Process Report) can be used to online debug if the communication is present but some errors are
found in data handling like wrong values, wrong bit allocation, wrong bit order, etc
Next we can observe the small area located at:

WW 0401

Each column has 16 bits (a word) and only one time per row we are shown the word indicator
(WB040100, so the next columns on the first row correspond to WW0402, WW0403 and WW0404)

5. Gain & Bias

Sometimes when communicating with other systems the raw analog (actual) value sent from the
subsystem to us, differs from the actual intended value (e.g. for 7 bar-g subsystem sends 15000 as a raw
value). The 3rd Party Vendor must indicate wheatear they use the standard data type definitions or not.
If they don’t then we will need to be informed of the minimum and maximum raw value their system is
using for a predefined interval.

In this scenario the vendor has sent the information needed.

Data type : 32 bit floating

Raw Min Range : 0

Raw Max Range : 32000

Next we need to scale the raw value received to the desired instrument range (150 … 800)
The standard scaling equation is : ax + b = y, where x is the raw value sent and y is the desired value to
show. The coefficients a and b are the Gain and Bias.

So for an x = 16000 (50% range) we want to show an y = 475

Below we can find the generalized formula for gain and bias :

Gain = (b-a)/(d-c)

Bias = (ad-cb)/(d-c)

Where

Raw Value Low is c

Raw Value High is d

Scale Low is a

Scale High is b

For our example gain = 0.0203125 and bias = 150, so for x = 16000 y = 0.0203125*16000 + 150 = 475

Setting Gain and bias to analog function blocks

PVI Block
MLD-SW Block

Note :

If the 3rd Party Vendor uses standard data type definitions no gain and bias need to be set but Signal
Conversion needs to be set to Communication Input/Output

Example :

3rd Party Vendor information :

We observe data type: 32S (32 bit signed integer) so a standard minimum value of -2147483648 and
maximum of 2147483648. In this case the gain remains 1 and bias 0.