Master station specification for user’s function (5578-E4-VP-IU-604-030)

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Butterfly Type Motor Operated Valve_Master station specification for user’s function

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BUTTERFLY TYPE MOTOR OPERATED VALVES

Master station specification for user’s function

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BUTTERFLY TYPE MOTOR OPERATED VALVES

Master station specification for user’s function

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© Copyright bA Tyco INTER

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© Copyright by BIFFI Italia. All right reserved i MDE205/Rev.0 A Tyco INTERNATIONAL LTD. COMPANY

REVISION LIST

Rev. Date Prepared Approved Description

0 07.09.10 C.D. A.A. Issued. Operative Guide related to DCM Software Rev.3.02.02.xx

ALL RIGHTS RESERVED

TITLE DCM Rev. 3.02.02 Operative Guide

BIFFI ITALIA has taken every care in collecting and verifying the documentation contained in this Opertaive Guide. The informations herein contained are reserved property of BIFFI ITALIA.


© Copyright by BIFFI Italia. All right reserved ii MDE205/Rev.0 A Tyco INTERNATIONAL LTD. COMPANY

Echelon, LONWORKS, Neuron 3150 are registered trade marks of Echelon Corporation. LONMARK is a registered trade mark of Echelon Corporation.


© Copyright by BIFFI Italia. All right reserved iii MDE205/Rev.0 A Tyco INTERNATIONAL LTD. COMPANY

INDEX

1. INTRODUCTION .............................................................................................................................. 1

1.1 INTRODUCTION TO LONWORKS PROTOCOL ............................................................................... 3 1.2 BUS COMMUNICATION TOPOLOGY ................................................................................................ 5

2. DCM FUNCTIONS ............................................................................................................................ 7

2.1 ACCESS TO THE SYSTEM ................................................................................................................ 7 2.2 NETWORK CONFIGURATION .......................................................................................................... 7 2.3 MODBUS COMMUNICATIONS ...................................................................................................... 8 2.4 GROUPS MANAGEMENT ................................................................................................................ 8 2.5 LOOP INTEGRITY CHECK ............................................................................................................... 9 2.6 DASHBOARD VIEW ........................................................................................................................ 9 2.7 COMMUNICATION LOOP EXTENSION – REPEATER ................................................................... 10 2.8 EXTENDED NETWORKS – OUTPUT MODULE .......................................................................... 11 2.9 HOT BACK UP CONFIGURATION .................................................................................................. 12

3. IDENTIFICATION OF PARTS AND COMPONENTS .............................................................. 13

3.1 DCM MANUFACTURING CODE ................................................................................................... 13 3.2 PARTS IDENTIFICATION ............................................................................................................... 14 3.3 TECHNICAL FEATURES ................................................................................................................ 15 3.4 FRONT PANEL .............................................................................................................................. 17

3.4.1 Switches .............................................................................................................................. 17 3.4.2 Keyboard and Display ........................................................................................................ 17 3.4.3 LED Signalling ................................................................................................................... 18

3.4.3.1 Local I/O Status ............................................................................................................................. 18 3.4.3.2 Communication Lines Status ......................................................................................................... 18 3.4.3.3 System Status ................................................................................................................................ 19

3.5 REAR PANEL ............................................................................................................................... 20 3.5.1 Input Supply ........................................................................................................................ 20 3.5.2 Output Supply ..................................................................................................................... 20 3.5.3 CPU Module ....................................................................................................................... 21

3.5.3.1 LAN Communication .................................................................................................................... 22 3.5.4 MODBUS Lines .................................................................................................................. 23

3.5.4.1 RS232-C PROTOCOL .................................................................................................................. 24 3.5.4.2 RS422 PROTOCOL ...................................................................................................................... 25 3.5.4.3 RS485 PROTOCOL ...................................................................................................................... 26

3.5.5 LONWORKS Interface Module .............................................................................................. 27 3.5.6 I/O Interface ....................................................................................................................... 29

3.6 SUMMARY OF THE CONNECTIONS ON THE REAR PANEL .............................................................. 30

4. SETTING FOR TYPICAL APPLICATIONS ............................................................................... 31

4.1 SINGLE STATION WITH NON-REDUNDANT BUS ........................................................................... 32 4.1.1 DCM Settings ...................................................................................................................... 32 4.1.2 System Behaviour ............................................................................................................... 33

4.2 SINGLE STATION WITH REDUNDANT BUS .................................................................................... 34 4.2.1 DCM Settings ...................................................................................................................... 34 4.2.2 System Behaviour ............................................................................................................... 35

4.3 REDUNDANT MASTER WITH REDUNDANT BUS ............................................................................ 36 4.3.1 DCM Settings ...................................................................................................................... 36

4.3.1.1 MODBUS Link Cable ................................................................................................................... 37


© Copyright by BIFFI Italia. All right reserved iv MDE205/Rev.0 A Tyco INTERNATIONAL LTD. COMPANY

4.3.2 System Behaviour ............................................................................................................... 38 4.4 REDUNDANT MASTER WITH SEVERAL LOOPS ............................................................................. 39

4.4.1 DCM Settings ...................................................................................................................... 39 4.4.2 System Behaviour ............................................................................................................... 40

5. OPERATOR INTERFACE ............................................................................................................. 41

5.1 MAIN SCREEN ............................................................................................................................. 42 5.2 NETWORK CONFIGURATION AND NODES MANAGEMENT ............................................................ 43

5.2.1 Configuration –Groups List ................................................................................................ 43 5.2.2 Configuration – Router List ................................................................................................ 45 5.2.3 Configuration – Node List .................................................................................................. 47

5.3 SUPERVISION OF THE COMMUNICATION NETWORK ..................................................................... 49 5.3.1 Supervision – Loop List ...................................................................................................... 49 5.3.2 Supervision – Dashboard ................................................................................................... 50 5.3.3 Supervision – Cable List ..................................................................................................... 51 5.3.4 Supervision – Memory Allocation List ................................................................................ 52

5.4 DEVICES CHECK SCREEN ............................................................................................................ 53 5.4.1 NETH and NETT Nodes ..................................................................................................... 53 5.4.2 ICONFDI Nodes ................................................................................................................. 55

5.4.2.1 Diagnostic Screen .......................................................................................................................... 57 5.4.2.2 Maintenance / Nameplate Screen .................................................................................................. 59 5.4.2.3 Configuration Screen ..................................................................................................................... 60 5.4.2.4 ICON2000 - On-board FDI Screen ............................................................................................... 61

5.4.3 VEM Nodes ......................................................................................................................... 62 5.4.4 GEN.I/O Nodes ................................................................................................................... 63

5.5 MASTER – SLAVE CONTROL SYSTEM .......................................................................................... 65 5.5.1 Master Slave ....................................................................................................................... 65

5.6 DIAGNOSTICS MENU ................................................................................................................... 67 5.6.1 Diagnostics ......................................................................................................................... 67

5.7 GENERAL CONFIGURATION SETTINGS ......................................................................................... 68 5.7.1 System ................................................................................................................................. 68 5.7.2 Login ................................................................................................................................... 69 5.7.3 Password ............................................................................................................................ 69 5.7.4 Clock ................................................................................................................................... 70 5.7.5 Info ...................................................................................................................................... 71 5.7.6 Ethernet .............................................................................................................................. 71 5.7.7 MODBUS Lines Setting ...................................................................................................... 72

5.7.7.1 MODBUS RTU Channels ............................................................................................................. 73 5.7.7.2 MODBUS TCP Channels .............................................................................................................. 73

6. CONFIGURATION FILE ............................................................................................................... 75

6.1 FILE HEADER [INFO] .................................................................................................................... 75 6.1.1 MODBUS map structure definition .................................................................................... 76

6.2 SECTION [TOPOLOGY] ................................................................................................................. 78 6.3 SECTION [GROUPS] ...................................................................................................................... 79 6.4 SECTION [NODETYPE] .................................................................................................................. 80 6.5 SECTION [DEVICES] ..................................................................................................................... 85 6.6 SECTION [FREE_MOD_VAR] ......................................................................................................... 86 6.7 SECTION [CABLELIST] ................................................................................................................. 87 6.8 LOCAL INPUT/OUTPUT CONFIGURATION ..................................................................................... 88

6.8.1 Local DO configuration ...................................................................................................... 88 6.8.2 Local DI configuration ....................................................................................................... 89

7. EXTERNAL OPERATOR INTERFACE ...................................................................................... 91

7.1 SETTING THE PC ETHERNET PORT ............................................................................................... 92 7.2 CONFIGURATION FILE TRANSFER ................................................................................................ 93 7.3 REMOTE TERMINAL ..................................................................................................................... 94

7.3.1 HyperTerminal Session ....................................................................................................... 94 7.4 SOFTWARE UPDATE VIA SERIAL LINE ......................................................................................... 95 7.5 MAINTENANCE STATION ............................................................................................................. 96


© Copyright by BIFFI Italia. All right reserved v MDE205/Rev.0 A Tyco INTERNATIONAL LTD. COMPANY

8. FUNCTIONAL PROCEDURES ..................................................................................................... 99

8.1 GET THE DCM WORKING ............................................................................................................ 99 8.2 NETWORK CONFIGURATION AND NODES MANAGEMENT .......................................................... 100

8.2.1 Creating a New Network without Configuration File ....................................................... 100 8.2.2 Configurating a Network with the Configuration File ..................................................... 101

8.2.2.1 Load Command Error Codes ....................................................................................................... 102 8.2.3 Routers Management ........................................................................................................ 103

8.2.3.1 Router Fault ................................................................................................................................. 103 8.2.4 Nodes Management .......................................................................................................... 104

8.2.4.1 Cancelling a Node from a Group ................................................................................................. 104 8.2.4.2 Cancelling a Group ...................................................................................................................... 104 8.2.4.3 Replacing a Node in the Network ................................................................................................ 105 8.2.4.4 Adding a Node to a Network ....................................................................................................... 105 8.2.4.5 Configuration Modes ................................................................................................................... 106

8.3 ACTIVATION OF LOOP INTEGRITY CHECK ................................................................................. 108 8.3.1.1 Rebuilding the Physical Wiring List ........................................................................................... 108 8.3.1.2 Enabling the Loop Integrity Check ............................................................................................. 110

8.4 CONFIGURATION FILE MANAGING ............................................................................................ 112 8.4.1 Transferring the Configuration to the Flash Memory ...................................................... 113 8.4.2 Retrieving the Configuration from the Flash Memory ...................................................... 113

8.5 RESETTING THE DCM ............................................................................................................... 114 8.6 SOFTWARE DOWNLOAD ON DCM ............................................................................................. 114 8.7 REPLACING BATTERIES ............................................................................................................. 114

APPENDIX A: DEFINITION OF THE MODBUS INTERFACE .................................................... 115

A.1 STRUCTURE OF THE MODBUS INTERFACE ............................................................................... 116 A.1.1 DI area – Internal Data zone ............................................................................................ 117 A.1.2 DI area – Field Image ...................................................................................................... 121

A.1.2.1 DI in ‘Object wise’ structure ....................................................................................................... 121 A.1.2.2 DI in ‘Function wise’ structure .................................................................................................... 121

A.1.3 DO area – Internal Data zone .......................................................................................... 122 A.1.4 DO area – Field Image ..................................................................................................... 122

A.1.4.1 DO in ‘Object wise’ structure ...................................................................................................... 122 A.1.4.2 DO in ‘Function wise’ structure .................................................................................................. 123

A.1.5 AI area – Field Image ....................................................................................................... 124 A.1.5.1 AI in ‘Object wise’ structure ....................................................................................................... 124 A.1.5.2 AI in ‘Function wise’ structure .................................................................................................... 124

A.1.6 AO area – Field Image ..................................................................................................... 126 A.1.6.1 AO in ‘Object wise’ structure ...................................................................................................... 126 A.1.6.2 AO in ‘Function wise’ structure .................................................................................................. 126

A.2 MODBUS PROTOCOL DETAILS ................................................................................................ 127 Function Code 01 (01 Hex) Read Coil Status................................................................................... 127 Function Code 02 (02 Hex) Read Discrete Input ............................................................................. 127 Function Code 03 (03 Hex) Read Holding Register ......................................................................... 127 Function Code 04 (04 Hex) Read Input Register ............................................................................. 128 Function Code 05 (05 Hex) Write Single Coil .................................................................................. 128 Function Code 06 (06 Hex) Write Single Register ........................................................................... 129 Function Code 08 (08 Hex) Loop Back Test..................................................................................... 129

Sub-function 00 (00 Hex) Return Query Data .............................................................................................. 129 Sub-function 01 (00 Hex) Restart Communications Option ......................................................................... 129 Sub-function 10 (0A Hex) Clear Counter and Diagnostic Register .............................................................. 129 Sub-function 11 (0B Hex) Return Bus Message Count ................................................................................ 130 Sub-function 12(0C Hex) Return Bus Communication Error Count ............................................................ 130 Sub-function 13 (0D Hex) Return Bus Exception Error Count ..................................................................... 130 Sub-function 14 (0E Hex) Return Slave Message Count .............................................................................. 130 Sub-function 18 (12 Hex) Return Bus Characters Overrun Count ................................................................ 130

Function Code 15 (0F Hex) Write Multiple Coils ............................................................................ 130 Function Code 16 (10 Hex) Write Multiple Registers ...................................................................... 131 Function Code 17 (11 Hex) Report Slave ID .................................................................................... 131 MODBUS Exception Responses ....................................................................................................... 132

APPENDIX B: CABLE SELECTION ................................................................................................. 133


© Copyright by BIFFI Italia. All right reserved vi MDE205/Rev.0 A Tyco INTERNATIONAL LTD. COMPANY

B.1 SPECIFICATION FOR 16AWG/1.3 MM – TWISTED PAIR CABLE ................................................... 134

APPENDIX C: ICON2000 COMMUNICATION INTERFACE .................................................. 135

C.1 ACTUATOR RUNTIME INPUT VARIABLES .................................................................................... 135 C.2 ACTUATOR OUTPUT VARIABLES ................................................................................................ 135 C.3 ACTUATOR SETUP AND CONFIGURATION VARIABLES ................................................................ 137 C.4 MAINTENANCE VARIABLES ....................................................................................................... 138 C.6 FACTORY COMMISSIONING VARIABLES (READ ONLY) ............................................................... 139 C.7 FAULT DETECTION FUNCTION CONFIGURATION ......................................................................... 140

APPENDIX D: PERFORMANCES ...................................................................................................... 141

D.1 DCM MEMORY CAPACITY ........................................................................................................ 141 D.2 FIELD BUS CONNECTIONS .......................................................................................................... 141 D.3 FIELD BUS COMMUNICATIONS ................................................................................................... 143 D.4 RESET TIME AFTER BUS INTERRUPTION .................................................................................... 143 D.5 TIME FOR CONTROL SWITCHING BETWEEN MASTER AND SLAVE UNITS ................................... 143


© Copyright by BIFFI Italia. All right reserved 1 MDE205/Rev.0 A Tyco INTERNATIONAL LTD. COMPANY

1. INTRODUCTION The DCM (Diagnostic Communication Master) is a component of the plant automation system and acts as an interface between the upper level of the control system and the field devices connected by a fieldbus network. The DCM offers the following advantages:

It supplies specific screens for nodes management: the operator achieves Maintenance functions without enlarging system architecture.

Data exchange between the control system and the DCM are limited to data related to plant supervision and control (actuators status and commands) avoiding the transmission of unused information.

The DCM does not use a proprietary protocol, but implements LONWORKS® protocol by Echelon. This is a very powerful industrial protocol that is successfully applied in a lot of application in Industrial Automation.

The DCM manages the following tasks by means of a modular architecture:

It establishes communication between a field composed of Biffi actuators series ICON and ICON2000 with LONWORKS interface and the upper level of the control system – DCS or PLC – through a MODBUS interface;

By means of its operator interface, it performs all the plant’s control and maintenance operations by way of a series of dedicated screens of the controlled devices;

It is the configuration tool for the fieldbus network including all the functions for the management of all devices. No other tools or licensed software are necessary.

Each device connected to the network is called “node”. The DCM unit can sustain a network composed of up to 300 nodes with an appropriate system layout as described in the next paragraphs. The DCM can manage the of the following types:

Name Description

ICON Intelligent unit for actuator control, integral with Biffi actuators series C and QTC

ICON2000 Second-generation of intelligent actuators

VEM Control unit for pneumatic actuators series RP

FDI / NET Control unit for devices with no control system for loop integrity

GenIO Generic I/O device for discrete and analogue signals The DCM unit is based on a modular architecture, and allows controlling several solutions in accordance with Customer requirements; typical structures are as follows:

LEVEL 1

LEVEL 2

LEVEL 3

AUTOMAT

SENSORS ACTUATORS

PROCESS

fieldbus fieldbus

A U T O M A T I O N



Single station with non-redundant bus

Single station with redundant bus

Master and Slave Station with redundant bus Master and Slave Station with redundant bus on several loops

NET 1 NET 2

DCM MODBUS Interface

LONWORKS Interface

OUT A OUT B IN A IN B

T

NET 1 NET 2


LONWORKS Interface


NET 1 NET 2


LONWORKS Interface


LAN

NET 1 NET 2


LONWORKS Interface


Output Module Rack IN NET 1 IN NET 2

NET 1 NET 2


LONWORKS Interface


LAN

NET 1 NET 2


LONWORKS Interface


LOOP A

NET 1 NET 2

LOOP B

NET 1 NET 2

LOOP X

NET 1 NET 2

. . . .



1.1 Introduction to LONWORKS Protocol In almost every industry today, there is a trend away from proprietary control schemes and centralized systems. Manufacturers are using open, off-the-shelf, chips operating systems and parts to build products that feature improved reliability, flexibility, international proven record, system cost and performance. LONWORKS technology is accelerating this trend by providing interoperability, robust technology, faster development, and scale economies. Devices in a LONWORKS network communicate using LONTALK®, the standardized language of the network. LONTALK consists of a series of underlying protocols that allow intelligent communication among various devices on a network. The protocol provides a set of services that allow the application program in a device to send and receive messages from other devices over the network with no need to know the topology of the network or the names, addresses, or functions of other devices. Support for network management services allows the remote network management tools to interact with devices over the network, including reconfiguration of network addresses and parameters, downloading of application programs, reporting of network problems and start/stop/reset of device application programs. LONTALK – and thus LONWORKS networks – can be implemented over basically any medium, including power lines, twisted pair, radio frequency (RF), infrared (IR), coaxial cable and fibre optics (FO). A control network is a group of “nodes”, each with one or more sensors or actuators, plus localized computational capability, that communicate over one or more media, using a standard protocol to control and monitoring application. Communication among the nodes may be peer-to-peer or master-slave; in either case, intelligence in the nodes permits the distribution of processing loads. If the control functions are also distributed, both system performance and reliability can be dramatically enhanced. LONWORKS is a networking platform created by Echelon. LONWORKS networks really describe a complete solution to the problem of control systems. A networked control system is significantly more powerful, flexible, and scaleable than a non-networked control system; and businesses can save and make more money building control networks over the long term than they can with non-networked control systems. Protocols today are generally designed to follow the ISO standard "Open Systems Interconnection Reference Model," which encompasses a full set of protocol features, and classifies them according to seven functional categories referred to as "layers". Thus the "seven layer ISO-OSI model". The LONTALK protocol implements all seven layers of the ISO-OSI model, and it does so using a mixture of hardware and firmware on a silicon chip. Features include media access, transaction acknowledgement and peer-to-peer communication, and more advanced services such as sender authentication, priority transmissions, duplicate message detection, automatic retries, client-server support, unicast/multicast/broadcast addressing and error detection and recovery. Reliable delivery is provided by using end-to-end acknowledgements made possible by the use of a seven layer OSI stack, 16-bit cyclical redundancy checks and, in the case of certain transceivers, the use of error correction algorithms. An integral part of the protocol used in LONWORKS networks is its unique media access technique, termed "predictive persistent CSMA, with optional priority and collision detection". It provides linear response to offered traffic load, predictable response time for heavily loaded networks, and consistent performance independent of network size.

1 - PHYSICAL

6 - PRESENTATION

2 - DATA LINK

3 - NETWORK

4 - TRANSPORT

5 - SESSION

7 - APPLICATION

User

Physical Medium



Interoperability is achieved by the introduction of the Standard Network Variable Type (SNVT): each node implements a set of communication objects that are defined according to the standardized data type SNVT.

The configuration of a LONWORKS network consists in establishing virtual connections among input and output communication objects belonging to the same SNVT type (binding).

During normal functioning, every time an output changes state, the variation is immediately propagated to the corresponding input element.

ACTUATOR

nvi_DriveOpen

nvo_ValveOpen

nvo_ValveClose

nvo_Opening

nvo_Closing

nvi_DriveClose

nvo_ValveOpen

ACTUATOR

#1

nvi_DriveOpen nvo ValveClose

nvo_Opening

nvo_Closing

nvi_DriveClose

nvi_input9

nvi_input10

nvi_input11

nvi_input12

nvi_input5

nvi_input6

nvi_input7

nvi_input8

nvi_input1

nvi_input2

nvi_input3

nvi_input4

D C M

nvo_ValveOpen

ACTUATOR

#2


nvo_Opening

nvo_Closing

nvi_DriveClose

nvo_ValveOpen

ACTUATOR

#3


nvo_Opening

nvo_Closing

nvi_DriveClose



R1 = 105Ω±1%, 1/8W C1,C2 = 100μF, 50V min.

1.2 Bus Communication Topology Standard DCM applications uses twisted pair cables to allow fieldbus communications. To achieve the best communication performance the network must be terminated on both sides of the line. The terminator is a simple RC circuit, defined by the LONWORKS1 protocol specifications and shown in the drawing. The terminators are necessary to avoid the propagation of echoes (reflections) that can be generated by the high transmission speed (78Kbps) and the network cable length. The DCM provides bus terminations by means of two circuits embedded in the DCM rack. The two circuits are indicated on the rear panel of the DCM as FDI1 and FDI2 and they act as two “nodes” specialised in managing the terminations. During network set-up the FDI nodes must be configured in the proper way:

Network Head (NET_H) is the FDI placed at network beginning; Network Tail (NET_T) is the FDI placed at network end.

This simple rule allows the DCM to drive a pseudo-loop structure in all the DCM typical applications and to achieve network redundancy as described in paragraph 2.5: ‘Loop Integrity Check’.

1 LONWORKS® FTT-10A Free Topology Transceiver User’s Guide Version 6 - Echelon® Corporation

R1 Network connection

C1

C2

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NETH

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2. DCM FUNCTIONS

2.1 Access to the System Access to DCM screens and availability for the performance of commands is regulated by an access control system based on the identification of operators and password control. The DCM defines the following four operators: OBSERVER

Can only view screens but cannot send commands or perform changes. No password needed.

OPERATOR Is in charge of the process and can send operational commands to all connected devices. For example, OPERATOR can enter the ICON actuators menu and send a close command.

MAINTAINER Is in charge of process maintenance and can access operational commands and the configuration of connected devices. For example, MAINTAINER can enter the ICON actuator configuration screen and change the parameters for the Timer function On Time.

ADMINISTRATOR The System Administrator has full control of the plant and manages the functioning, maintenance and communication network. For example, in addition to the rights of the previous two operators, ADMINISTRATOR can modify the communication network by adding or deleting nodes, or creating and modifying groups. Furthermore, he assigns passwords to other operators.

Apart from simple reading, each operator must first be identified before being allowed to perform an operation. Login function is available at System | Login screen as described in paragraph 5.7.2: ‘Login’.

2.2 Network Configuration Before the system composed by DCM and field devices become operational, it must be configured. Configuration involves both the DCM, which has to create the image of each field device in its internal memory and to set the MODBUS interface map, and every field device which has to be set with a network communication address and to be instructed on the network variable to be exchanged with the DCM. In other words the system configuration builds the links among field devices and the DCM that have been described in the paragraph 1.1: ‘Introduction to LONWORKS Protocol’. The user is not required to know any communication detail, nor to be a skilled operator of software configuration program. The DCM manages itself these critical tasks by built-in functions accessible via softkeys available on the operator interface. The DCM based the network configuration on a text file where each field device is indicated with its tag name and the plant composition is described via simple rules as described in chapter 6: ‘CONFIGURATION FILE’. Operative procedures on how to configure different kind of networks in are indicated in paragraph 8.2: ‘Network Configuration and Nodes Management’.



2.3 MODBUS Communications The DCM unit supplies to the higher level plant control system (DCS, SCADA or PLC) the data coming from the field units and forwards them the commands thus enabling the full control of the plant via the well known MODBUS protocol. The DCM acts as a gateway between the MODBUS line and the LONWORKS network. DCM can be equipped with specific CPU cards in order to allow the following configurations:

Channel A Channel B Channel C Channel D LAN MODBUS RTU MODBUS RTU n.a. n.a. MODBUS TCP

or

Channel A Channel B Channel C Channel D LAN n.a. MODBUS RTU MODBUS TCP MODBUS TCP MODBUS TCP

In order to grant redundant communications, all serial lines are completely independent. The hardware details are described in paragraph 3.5.4: ‘MODBUS Lines’ while configuration parameters for each serial port are available in System | Modbus screen as explained in paragraph 5.7.7.1: ‘MODBUS RTU Channel’ and in paragraph 5.7.7.2: ‘MODBUS TCP Channel’. The data available at the MODBUS interface are defined in the DCM configuration file; definition and rules are explained in chapter 6: ‘CONFIGURATION FILE’. ‘APPENDIX A: DEFINITION OF THE MODBUS INTERFACE’ of the present manual describes the implementation of the MODBUS interface of the DCM and the details of the available signals.

2.4 Groups Management A special mode for the management of nodes called “group management” has been developed for an easy control of the field devices connected to the DCM. With this mode the devices connected to the DCM can be grouped into homogeneous sets (for ex. all the actuators installed in a specific area of the plant: Pumping Station, Blending, etc.) and separately visualised on the DCM screen. In this way a network composed of a number of actuators can be logically divided into smaller, more manageable portions. The management of the whole plant through groups ensures a more flexible view of the system totally independent of the physical connection between field nodes. The creation of new groups is left to the user, who must observe the following simple rules:

Up to 99 groups can be added; each group can list up to 126 nodes. However the max number of nodes the DCM can manage is 300.

Each group must be composed of nodes connected to the same loop. On each loop more groups can be defined. Each device can belong to a single group. Each group must consist of homogeneous devices The sequence of nodes within the group is independent of the physical connection sequence of the

communication bus. A unique group may contain both NET_x connected in the same loop.

Groups may be created directly at the operator interface by the function available at Configuration screen as described in paragraph 5.2.1: ‘Configuration – Group List’ or defined in the configuration file as described in chapter 6: ‘CONFIGURATION FILE’. An interesting characteristic of group management is the possibility of sending configuration commands to the whole group by a specific function in the Node List screen of the selected group as described in paragraph 5.2.3: ‘Configuration – Node List’. This feature is used to set those parameters that must be identical for all the devices, such as for example the heartbeat value for actuators type ICONFDI.



2.5 Loop Integrity Check The DCM has a sophisticated system for controlling the integrity of the communication loop based on the reconstruction of the physical sequence of node wiring. By way of an automatic procedure, the DCM recreates the physical list for each communication loop; the nodes wiring sequence is independent of the MODBUS map and of the way the groups are organised into. After establishing the sequence, the NET_x nodes at the loop extremes perform the continuity verification; this ensures a tight check independently of the DCM activity. Only in case of cut-off communication (cut cable, ground wire, or short circuit between the bus conductors) does the DCM itself provide the closest possible terminators to the failure to establish a new connection to the still communicating nodes. Details about this function are in paragraph 8.3: ‘Activation of Loop Integrity Check’.

2.6 Dashboard View Dashboard view is an innovative method available in Supervision screen to display the actual state of a large number of nodes connected in the same loop. The nodes are listed following either the memory allocation sequence inside the DCM or the wiring sequence of each loop as it results after the automatic procedure for the reconstruction of the physical sequence of node wiring. This last view method may result very clear especially for large plants with hundreds of field devices in several loops. Further the communication status in Dashboard view it is also possible to discover in one shot the field devices that are in not operative condition due to application alarm as Thermostat trip, Jammed Valve, etc. Details of Dashboard screen are at paragraph 5.3.2: ‘Supervision – DashBoard’.

LAN

NET 1 NET 2

DCM Master


NETH NETT

NET 1 NET 2

DCM Slave


LAN

NET 1 NET 2

DCM Master


NETH NETT

NET 1 NET 2

DCM Slave




2.7 Communication Loop Extension – REPEATER In the typical LONWORKS system structure the fieldbus network is composed of “segments” with the following characteristics:

total length less than 1400 meters; 60 devices connected;

In the DCM architecture the segment is a part of the ‘loop’. In case that the total bus length exceeds the maximum segment length or the total number of nodes to be connected in the loop is more than 60 it is necessary to split the loop in more segments: each segment is connected to the others by means of Repeater. The Repeater acts as a signal amplifier: data received from one side are regenerated and transmitted to the other side. The Repeater is not allocated in the DCM memory and it is not necessary configure it. In case it is powered off the system reacts as in case of a cable interruption. To let working the Loop Integrity Check system in case of loop composed of two or more segments it is recommended to put a further Repeater between the nodes NET_H and NET_T. This Repeater is indicated as “Internal Repeater” because it is normally hosted in the DCM cabinet The “Internal Repeater” allows to maintain the segment length in the specified limit when the Loop Integrity Check has detected a bus interruption. Using Repeaters the total loop capacity varies as follows:

Recommended total nodes in the loop

Total loop length in meters

Number of segments

Number of field Repeaters

Number of internal

Repeaters 60 1400 1 0 0

120 2800 2 1 1 120 4200 3 2 1 120 5600 4 3 1

Theoretically the number of nodes increases with the number of segments, but it is advisable not to overload a single loop with more than 120 actuators to avoid saturating the channel capacity. It is recommended not to exceed the number of three Repeaters per loop to avoid introducing delays in data packet propagation.

NET 1 NET 2


LONWORKS Interface


LAN

NET 1 NET 2


LONWORKS Interface


R

R



2.8 Extended Networks – OUTPUT MODULE In the case of a large network with more than 120 actuators or with a long communication network, the solution with Repeaters may not be sufficient. In this case it is preferable to divide the plant in more loops that are all connected to the same couple of DCM by means of an Output Module Rack. The composition of loops in the field follows the same rules shown in the previous paragraph; the communication speed among the devices connected in the loop is still at 78Kbps, but the DCM is equipped with the faster transceiver TPT/XF-1250 that works at 1,25Mbps to be able to manage the traffic coming from all the loops. Internally Output Module Rack is equipped with specific devices called Routers that interface together the two different speed channels. Details about the configuration of Routers are given in paragraph: 8.2.3: “Routers Management”. An Output Module Rack is a modular device that allow managing a multiple loop structure. A single rack may connect up to 6 field loops. It is possible to link up more racks together to make a network where a DCM system can manage up to 18 loops. More details are in the document “OMR- Output Module Rack” rev. 0.1.


NET 1 NET 2


LONWORKS Interface


LAN

NET 1 NET 2


LONWORKS Interface


LOOP A

NET 1 NET 2

LOOP B

NET 1 NET 2

LOOP X

NET 1 NET 2

. . . .



2.9 Hot Back Up Configuration The typical layout with redundant DCM (Master and Slave) ensures uninterrupted control by the DCS in case of DCM Master fault. The working behaviours of the different plant layouts are described in paragraph 4.3: ‘Redundant Master with Redundant Bus’ and in paragraph 4.4: ‘Redundant Master with Several Loops’; both are basically the same from the DCS point of view. To grant a higher system availability it should be necessary that also a repairing service on a faulty Slave does not affect Master functioning while it is active with control. To reach this goal it is necessary to add a unit called Hot Back Up module. A Hot Back Up module is a 1HE rack module placed between the DCM Master and the Slave. It is driven by the Enable Out contact of the Slave unit and it addresses the MODBUS lines from DCS to the DCM with control.

NET 1 NET 2


LONWORKS Interface


LAN

NET 1 NET 2


LONWORKS Interface


DCS


NET 1 NET 2


LONWORKS Interface

LAN

NET 1 NET 2


LONWORKS Interface


DCS

Hot Back Up module

IN A IN B

OUT1 A OUT1 B OUT2 A OUT2 B



3. IDENTIFICATION OF PARTS AND COMPONENTS

3.1 DCM Manufacturing Code Each DCM is equipped with a label on the rear side of the unit, indicating its manufacturing code. This code is generated during order entry, according to specifications and Customer’s requirements.

Secondary MODBUS line

Primary MODBUS line

Optional card

Transceiver type

2 9 3 D C M 5

0 0 x x

1 0 x x

The Host Communication protocol can be configured independently on each line. The relevant code to the type of protocol used can take the following values: Channel A: MODBUS RS232-C 0 Channel A: MODBUS RS422 1 Channel A: MODBUS RS485 2 Channel A: Not active Channel C and D: MODBUS TCP (only with 493CPU3000)

3 Channel B: MODBUS RS232-C 0 Channel B: MODBUS RS422 1 Channel B: MODBUS RS485 2 These indications can help identify the composition of the supplied station and guide the user in reading the relevant parts of this User’s Manual.

SM M M

Output Module

M S



3.2 Parts Identification The DCM has a completely modular structure, including removable parts and cards, which can be separately ordered as spare parts.

19” rack complete with card guide and internal bus: 493RCK1000 Front panel complete with keyboard and display: 493PAN2000 Input supply module: 493ALI1000 Output supply module: 493REL1000 I/O interface module: 493IOD1000 CPU module: 493CPU2000 or 493CPU3000 Field bus interface module: 493NET1002 for DCM 293DCM50xxx

493NET2000 for DCM 293DCM51xxx The modules can be seen on the rear panel, as shown in the picture:

Fieldbus interface 493NET1002 in DCM cod. 293DCM50xxx 493NET2000 in DCM cod. 293DCM51xxx

I/O Interface 493IOD1000

Input supply 493ALI1000

CPU Module 493CPU2000 (shown in the figure) or 493CPU3000

Output supply 493REL1000



3.3 Technical Features Mains Supply AC: from 87 to 264Vac - 50/60Hz

Selectable values: 110V; 120V; 230V; 240V. DC: 24V

Power 50VA

Current drain @230Vac: inrush 150mA, typical 100mA @24Vdc: inrush 1150mA, typical 500mA

External supply protection @230Vac fuse 5x20, 250V, 2A, Fast-acting @110Vac fuse 5x20, 250V, 4A, Fast-acting

Internal supply protection resettable fuse (MultiFuse protector)

Power supply output 12Vdc out; +10/-20%; max current 1A No internal fuse protection

Battery 2 x 1,5V Alkaline batteries, AA type. IMPORTANT: the batteries have to be replaced when the relevant indication is shown in the screen System. This operation must be done while the DCM is powered

Fieldbus protocol Protocol LONWORKS Transmission media: Twisted pair @78Kbps (cod. 293DCM50xxx) Twisted pair @1.25Mbps (cod. 293DCM51xxx)

Local DI 4 opto-isolated inputs Minimum input isolation: 500Vdc Minimum voltage input high: 4.75Vdc Maximum voltage input low: 0.2Vdc Maximum input voltage: 24Vdc Isolated 12Vdc output available on the rear panel.

Local DO 4 volt-free contacts, normally open Nominal resistive load: 0.5A @110Vac; 1A @24Vdc Maximum working voltage: 125Vac, 60Vdc Output isolation: 400Vdc

Local display Monochromatic graphic display: - text mode: 40 characters x 16 lines - graphic mode: 240x128 pixel Visible area: 114mm x 64mm Contrast: keyboards adjustable.

Local keyboard Front-panel integrated, with 16 keys and 4 multi-function “softkeys”

LEDs 4 green LEDS: status of available inputs 4 green LEDS: status of outputs 5 red LEDS: status of serial lines 2 red LEDS: power available 1 red LED: bus active 5 various LEDS: status of the DCM

Dimensions length: 480mm; width: 300mm; height: 132mm

Weight 8 kg

Housing 19” - 3HE rack, suitable for cabinet mounting

Working temperature 0 ÷ 50°C



Communication ports

CPU Model 493CPU2000 Channel A

Serial Line: RS232-C or RS422 or RS485 Protocol: MODBUS RTU Baud Rate: 300, 600, 1200, 2400, 4800, 9600; 19200; 38400,

57600 Bit No. 7; 8 Parity None; Even; Odd Stop Bit 1; 2

Channel B Serial Line: RS232-C or RS422 or RS485 Protocol: MODBUS RTU Baud Rate: 300, 600, 1200, 2400, 4800, 9600; 19200; 38400,


Configuration Serial Line: RS232-C Baud Rate: 38400

LAN 2-ports switch Serial Line IEEE 802.2 Ethernet 10Base-T Protocol: FTP; UDP

CPU Model 493CPU3000 Channel A

Serial Line: RS232-C or RS422 or RS485 Protocol: MODBUS RTU Baud Rate: 300, 600, 1200, 2400, 4800, 9600; 19200; 38400,


Channel B Serial Line: RS232-C or RS422 or RS485 Protocol: MODBUS RTU Baud Rate: 300, 600, 1200, 2400, 4800, 9600; 19200; 38400,


Channel C

2-ports switch Serial Line IEEE 802.2 Ethernet 100Base-T Protocol: MODBUS TCP/IP

Channel D

2-ports switch Serial Line IEEE 802.2 Ethernet 100Base-T Protocol: MODBUS TCP/IP

Configuration Serial Line: RS232-C Baud Rate: 115200 Bit No. 8 Parity None Stop Bit 1

LAN 2-ports switch Serial Line IEEE 802.2 Ethernet 100Base-T Protocol: FTP; UDP



3.4 Front Panel

3.4.1 Switches On the front panel there are two switches and the relevant LEDs: POWER main switch: position “O” = OFF

position “I” = ON When the DCM is correctly powered, the red LED above POWER switch is on; this shows a 5V voltage is present in the electronic cards. An indication of 12Vdc output voltage is also available.

BUS bus switch: position “O” = DCM not connected to the field bus

position “I” = DCM connected to the field bus When the bus switch is in position “I” and the DCM is enabled for bus control, the relevant red LED is on. In this condition the DCM is physically connected to the bus. In a Master / Slave architecture the bus indication will turn off on the Master station once the Slave station takes control.

3.4.2 Keyboard and Display The DCM is equipped with a powerful interface, which allows the local operator to have full control of the plant even though the other interfaces (DCS, Configuration terminal or Local supervisor) are not active. The interface consists of a graphic display and a 20 keys keyboard: 10 numeric keys (0 to 9), Enter, Clear (C), Minus (-), Decimal point (.), Page up (↑), Page down (↓) and 4 multi-function keys.



3.4.3 LED Signalling On the front panel the LED indications of the following functions are available:

local I/O status communication lines status system status

3.4.3.1 Local I/O Status The status of each local input and output available on the DCM is indicated. in #1, in #2, in #3, in #4 4 green LEDS corresponding to the input signals available at the

connector on the rear panel. The green LED is on when a voltage is applied to its corresponding pin.

out #1, out #2, out #3, out #4 4 green LEDs corresponding to the output signals available at the

connector on the rear panel. The green LED is on when the relevant relay is energised.

3.4.3.2 Communication Lines Status The status of the serial lines is indicated on the front panel by means of the relevant five red LED’s: Name Mode Active Unit Back-up Unit

Line A

flashing MODBUS RTU active on Channel A or MODBUS TCP active on Channel C or D

none

on MODBUS RTU error on Channel A or MODBUS TCP error on Channel C or D

none

Line B flashing MODBUS RTU active on Channel B none

on MODBUS RTU error on Channel B none

LAN flashing communication active with the Back-up DCM communication active with the Active DCM

on communication error with the Back-up DCM communication error with the Active DCM

Config flashing the DCM is updating its internal database from the external PC

the DCM is updating its internal database from active unit via LAN

Loc. Sup flashing active communication with an external line (optional).

active communication with an external line (optional).



3.4.3.3 System Status The status of the DCM is constantly indicated by 5 LEDs: Name Mode Active Unit Back-up Unit

System OK on the DCM has successfully configured the internal fieldbus interface card during start-up

Stand by

off the DCM is not in stand by none

on the active station is leaving control to the other unit none

flashing the DCM was set as Master and the relevant Slave has taken control.

the DCM is in Slave mode i.e. the DCM has been set as a Slave and it is ready.

Run flashing the DCM has the control none

Maint

on at least a field device has not been yet configured none

flashing the DCM is reading all the variable from the plant to update the internal image of the field

none

Field error

on at least one of the field nodes does not communicate. ‘Field error’ indication will be turned off once the communication returns to normal

at least one of the field nodes near to the Slave unit in stand-by (NET_T or Router) does not communicate. ‘Field error’ indication will be turned off once the communication returns to normal

flashing

the system has found a network error in the communication loop of a redundant structure (open circuit, short circuit or earth) and the control system has fixed the fault

none



3.5 Rear Panel DCM is composed of several modules arranged in a separate rack as shown in the picture

3.5.1 Input Supply On this module two supply inputs are available: 24Vdc IN: 24Vdc input supply AC supply input AC supply; this input consists in a main switch, a fuse-holder and a voltage

selector.

IMPORTANT: The AC supply voltage must be selected before powering the unit.

The selection of input supply among the possible values 110V, 120V, 230V or 240V is made by the appropriate positioning of the fuse-holder block so that the selected voltage indication is visible from the window on the rear panel.

3.5.2 Output Supply This module gives a 12Vdc voltage for general purposes. It can be used to supply the input signal of the I/O interfaces signals.

Fieldbus Interface

I/O Interface

Input Supply

CPU Module 12Vdc Output Supply

230



3.5.3 CPU Module In the DCM can be housed two types of CPU modules depending on the Customer’s requirement about the communication serial lines. The CPU module 493CPU2000 is suitable for redundant MODBUS RTU communications: IN A, IN B lines for connection to a superior control level (PLC or DCS) with a MODBUS RTU

protocol. These lines can be set as RS232-C, RS422 or RS485: see the following paragraphs for details on the cables and pin-out.

OUT A, OUT B on a Slave unit these lines must be connected to the Master station so as to ensure redundancy of the serial communication lines. See chapter 4: ‘SETTING FOR TYPICAL APPLICATIONS’for further details.

The CPU module 493CPU3000 is suitable for redundant MODBUS RTU and TCP communications: IN C, IN D input plugs for MODBUS TCP protocol.

OUT C, OUT D output plugs for MODBUS TCP protocol since the Ethernet ports are equipped with an integrated 2-port switch.

On both model the following parts can be identified: BATT. Battery holder, suitable for two alkaline batteries AA type, 1,5V

M/S MASTER/SLAVE switch: it configures the DCM as a Master or Slave unit. When the switch in set to the right-end position the DCM is configured as Slave, that is, as a back-up unit for a functioning Master station. More details are given in chapter 4: ‘SETTING FOR TYPICAL APPLICATIONS’.

EN. IN input contact: if CLOSED, the DCM is physically connected to the field bus. On a Slave unit or on a non-redundant unit the contact must be closed. On a Master unit the contact must be connected to the relevant Slave unit.

EN. OUT output contact: on a Slave unit, this contact controls the Master’s EN. IN contact.

LAN port of the Ethernet line between Master, Slave and configuration PC. The CPU module is equipped with an integrated 2-port switch.



CONF. Line for PC connection for the serial software upgrades operations. This is an RS232-C serial line: see the following paragraph for details of the cable and pin-out.

The lower level control of the communication, each serial post is equipped with 2 LEDs: red LED turns on when transmitting green LED turns on when receiving The LEDs can be seen between the connectors of input lines IN A and IN B. The lower pair is referred to Line A, the upper pair to Line B. The indications are only consistent if the cable is connected: this is particularly true for protocols RS422 or RS485, where the specific hardware can give wrong indications if the communication line is absent.

3.5.3.1 LAN Communication An Ethernet line with RJ45 connector is used to communicate between the Master and Slave DCM units. In order to ensure more flexibility for the connection to other devices, the DCM is equipped with an internal 2-port switch. Characteristics Max length 100 metres Cable standard Standard cable Category 5 UTP.



3.5.4 MODBUS Lines The CPU Modules can manage simultaneous MODBUS communications over different serial lines. The two CPU modules offers the following combination:

Line 1 2 3 LAN Channel A B - L

CPU model 493CPU2000 √ √ MODBUS RTU - RS232-C / RS422 / RS485 lines √ MODBUS TCP

Depending on the serial port configuration the CPU model 493CPU3000 can have the following two settings:

Line 1 2 3 LAN Channel A B - L

CPU model 493CPU3000 √ √ MODBUS RTU - RS232-C / RS422 / RS485 lines √ MODBUS TCP

Line 1 2 3 LAN

Channel C B D L

CPU model 493CPU3000 √ MODBUS RTU - RS232-C / RS422 / RS485 lines √ √ √ MODBUS TCP

Each serial port shall be individually configured: the selection of serial line is made during factory commissioning according to Customer’s requirement. The pin-out of the physical ports, depending on the selected serial protocol, is described in the following paragraphs.



Pin Description

2 Rx

3 TX

5 Gnd

3.5.4.1 RS232-C PROTOCOL When the manufacturing code indicates that the ports A or B have been configured to work with protocol RS232-C the physical ports have the following pin-out (see table). The CONF. configuration port only works in RS232-C. Characteristics Max length 15 metres Cable 5 x 22 AWG; the shielding must be connected to the connector metallic enclosure. Cable schematics

DCM 2

3

5

Rx

Tx

Gnd

PLC/DCS Rx

Tx

Gnd



Pin Description

1 Tx 422 +

2 Rx 422 +

3 Rx 422 -

4 Tx 422 -

5 0V reference

9 +5V reference

3.5.4.2 RS422 PROTOCOL When the manufacturing code indicates that the ports A or B have been configured to work with protocol RS422 the physical ports have the following pin-out (see table). Characteristics Max length 1200 metres Cable 4 x 22 AWG; 2 pairs of twisted pair cable with double shield. The outer shield

should be connected to the metallic enclosure of the connector, while the inner shield must be connected to pin 5. If the cable is long, also connect the 0V reference signal between the stations.

Cable schematics NOTE: For the good functioning of the communication line it is necessary to put a Line Terminator Rt (120 Ohm) at both ends of the RS422 line as indicated in the figure. It is also recommended to implement in one location of the whole Serial Bus a line polarization circuit made of pull-up and pull down resistors. The value of those resistors must be between 450 Ohm and 650 Ohm. Normally the line polarization is placed on the PLC / DCS side.

Rt

Rx +

Rx -

1

4

5

2

3

DCM

Rt

Tx +

Tx -

0 V

Rx +

PLC/DCS Rx -

Tx +

Tx -

0 V

9 +5 V

Pull up

5V

Pull up

5V

Pull down

0 V

Pull down

0 V



Pin Description

1 Data +

4 Data -

5 0V reference

9 +5V reference

3.5.4.3 RS485 PROTOCOL When the manufacturing code indicates that the ports A or B have been configured to work with protocol RS485 the physical ports have the following pin-out (see table). Characteristics Max length 1200 metres Cable 2 x 22 AWG; a pair of twisted pair cables with double shield. The outer shield

should be connected to the metallic enclosure of the connector and the inner shield should be connected to pin 5. In case of a long cable, connect also the 0V reference signal between the stations as shown below.

Cable Schematics NOTE: For the good functioning of the communication line it is necessary to put a Line Terminator Rt (120 Ohm) on the first and the last device on the RS485 line as indicated in the figure. It is also recommended to implement in one location of the whole Serial Bus a line polarization circuit made of pull-up and pull down resistors. The value of those resistors must be between 450 Ohm and 650 Ohm. Normally the line polarization is placed on the PLC / DCS side.

X -

1

5

4 DCM Rt

X +

0 V

PLC/DCS

0 V

9 +5 V

RtX +

X -

Pull up

5V

Pull down

0 V



3.5.5 LONWORKS Interface Module The Fieldbus Interface Module of the DCM is composed of the DCM LONWORKS Interface and of two FDI circuits

The following parts can be identified: DCM LONWORKS Interface

The Service Push-button and the Service LED are related to the internal LONWORKS Interface and are available to Service only.

Name Colour Description

SERVICE LED Yellow Status of the LONWORKS communication interface of the DCM. off node is working regularly flashing node not configured, or watchdog timer tripped on node not working

SERVICE PUSH-BUTTON

When the Service push-button is pressed, the DCM internal LONWORKS interface sends an identification string on the fieldbus.

WARNING: using the DCM Service Pin push-button instead of the FDI one may damage the

LONWORKS interface of the DCM unit. FDI nodes

Each FDI node has its own indication available on the rack panel. Depending on the DCM hardware configuration the number of FDI cards mounted on the DCM may vary:

SERVICE PUSH-BUTTON

SERVICE LED

FDI 1 Status FDI 2 Status FDI 1 Network FDI 2 Network



Pin Description

1 Bus +

2 Bus -

DCM code 293DCM51xxx No FDI mounted DCM code 293DCM50xxx Two FDI mounted For each FDI card the Service Pin (Button and LED) and 4 red LEDs are available, which provide the information on the working status of the communication loop integrity control system.

Name Colour Description LED 1 Red off relay B is turned on the terminator T.

on relay B is connected to the field. LED 2 Red off relay A is turned on the terminator T.

on relay A is connected to the field. LED 3 Red off the FDI algorithm is disabled.

on the FDI algorithm enabled but not active. flashing the FDI algorithm is working.

LED 4 Red off no network fault has occurred. on the network fault has been isolated.

SERVICE LED Yellow Status of the LONWORKS communication interface of the FDI. off node is working regularly flashing node not configured, or watchdog timer tripped on node not working

SERVICE PUSH-BUTTON

When the Service push-button is pressed, the FDI sends an identification string on the fieldbus.

NET 1, NET 2 connections to the field bus network: according to the

manufacturing code, one or two ports will be active. The connectors have the following pin-out:

Characteristics Cable for the right selection of the communication cable carefully follow instructions at

‘APPENDIX B: CABLE SELECTION’. Cable schematics NOTE: the connection at pins 1 and 2 is not affected by polarity.

1

2

1

2

A B

T T

to field from field

LED 1

LED 2

LED 3

LED 4

SERVICE LED

SERVICE PUSH-BUTTON



3.5.6 I/O Interface On the I/O Interface Module there are the terminals of 4 digital inputs and 4 digital outputs:

The connector pin-out is described as follows: Digital outputs can be managed by ‘equations’ written in the configuration file of DCM as described at paragraph 6.8.1: ‘Local DO configuration’ or, alternatively, can be controlled by DCS via MODBUS line as described in ‘APPENDIX A: DEFINITION OF THE MODBUS INTERFACE’. Digital inputs can gather signals coming from the cabinet where DCM is mounted (e.g. thermostat switch for high temperature, door open switch, etc) and transmit the current status of these inputs to DCS via MODBUS as described in ‘APPENDIX A: DEFINITION OF THE MODBUS INTERFACE’. Furthermore it is possible to use the physical inputs as trigger for commands to the nodes in the field via MODBUS communications as described in paragraph 6.8.2: ‘Local DI Configuration’. Examples: Input signal reading Output signal control

Input # Pin Description

1 1 Signal +

2 Signal -

2 3 Signal +

4 Signal -

3 5 Signal +

6 Signal -

4 7 Signal +

8 Signal -

Output # Pin Description

1 9 N.O. contact

10 Common

2 11 N.O. contact

12 Common

3 13 N.O. contact

14 Common

4 15 N.O. contact

16 Common

NET 1 NET 2

DCM

2 1 IN. #1

DI AREA 1 Physica input #1 2 Physica input #2 3 Physica input #3 4 Physica input #4 … …

MODBUS INTERFACE

+ Vext

- Vext

4 3 IN. #2

6 5 IN. #3

8 7 IN. #4

NET 1 NET 2

DCM

10 9 OUT. #1

DO AREA 1 Physica output #1 2 Physica output #2 3 Physica output #3 4 Physica output #4 … …

MODBUS INTERFACE

+ Vext

- Vext

12 11OUT. #2

14 13OUT. #3

16 15OUT. #4



3.6 Summary of the Connections on the Rear Panel All the connections between the DCM, the field and the Slave unit (if present), are located on the rear side of the unit. The following connectors are available for the relevant communication lines:

Port Name Connector Type on the Rear Panel

Power supply Socket according to CEE22 norm for 220-110V, with a power switch

24Vdc IN Two screw terminals for 24Vdc

Line A MODBUS input IN A DIN 9 pins male

Line A MODBUS output OUT A DIN 9 pins male

Line B MODBUS input IN B DIN 9 pins male

Line B MODBUS output OUT B DIN 9 pins male

Line C MODBUS TCP IN C OUT C 2 port switch - RJ45 (only on CPU model 493CPU3000)

Line D MODBUS TCP IN D OUT D 2 port switch - RJ45 (only on CPU model 493CPU3000)

Configuration port CONF. DIN 9 pins male

Ethernet Line LAN 2 port switch - RJ45

LONWORKS bus port NET1 Two screw terminals, 2 poles in line

LONWORKS bus port NET2 Two screw terminals, 2 poles in line

Digital inputs IN Screw terminals, 8 poles in line (4 inputs - 2 wires each)

Digital outputs OUT Screw terminals, 8 poles in line (4 outputs - 2 wires each)

Output voltage for digital inputs 12Vdc Screw terminals, 2 poles in line (+ 12V; + 0V)

Enable input En. IN Screw terminals, 2 poles in line

Enable output En. OUT Screw terminals, 2 poles in line



4. SETTING FOR TYPICAL APPLICATIONS This chapter describes how to configure and set the DCM unit for the most common applications. In all the possible cases on the DCM is loaded the same software and the different behalf of the unit is given by the following

The setting of the switch M/S The condition of the physical input EN.IN and the physical output EN.OUT Configuration File declaration as described in chapter 6: ‘CONFIGURATION FILE’.

M/S switch defines if the unit is a Master or a Slave and it determines the functioning respect to the field devices and the other unit. EN.IN is a physical input that enables the DCM fieldbus communication when it is closed. EN.OUT is a physical output that provides the enabling to the Master unit in a redundant system.

M/S switch

EN. OUT and EN.IN



R1 = 105Ω±1%, 1/8W C1,C2 = 100μF, 50V min.

4.1 Single Station with Non-redundant Bus This is the simplest schematic, where the DCM is connected to a network with bus structure. For this kind of structure the following typical rules of the LONWORKS protocol apply: • To reach the max bus length the network must be

terminated on both sides of the line. The terminator is a simple RC circuit, defined by the LONWORKS1 protocol specifications and shown in the drawing. If the terminators are not present, the bus length will be considerably less. In order to simplify installation the internal FDI should be set as NETH type, so that the DCM network is correctly terminated. To reach the bus maximum length it is necessary to add an external RC circuit to the other end of the network.

• Up to 60 devices (for ex. ICON2000 actuators) can be

connected to each segment. • to increase the total bus length or the total number of nodes in the loop, it is necessary to use a

repeater or an NCD device. Even though this bus structure is non-redundant, the DCM is equipped with two serial ports that ensure a redundant connection to the Host.

4.1.1 DCM Settings In this case the DCM manufacturing code will be:

293DCM500xx where x is the indication of the current setting of the MODBUS communication lines as explained at paragraph 3.1: ‘DCM Manufacturing Code’. The DCM unit is set as follow:

M/S switch on position M

The enable contact EN. IN is kept closed by a jumper

1 LONWORKS® FTT-10A Free Topology Transceiver User’s Guide Version 6 - Echelon® Corporation

R1 Network connection

C1

C2

NET 1 NET 2


LONWORKS Interface


T



The configuration of the two internal FDI cards is shown

in the drawing: the FDI circuit monitored by indication FDI 1 must be configured as NETH node so as to enable the internal termination, while the other FDI circuit, monitored by indication FDI 2, must be left as non configured.

The following drawing shows the connection at the rear panel:

4.1.2 System Behaviour Normal mode the Host is connected to ports A or B of the DCM; the DCM station is

active and communicates with the field. Bus interrupted the DCM station cannot communicate with all the field units therefore its

image of the field is no longer complete; in this case the DCM continues to exchange the available data with the Host.

DCM out of order the DCM cannot communicate with the field. Restarting of the DCM the station regains control when it is no longer out of service, i.e. after the

intervention of the operator that removes the fault, or once its cause disappears (e.g. power returns after it was missing).

Lines A and B both lines are simultaneously active so the Host can use indifferently either

one: the DCM signals any fault of its serial lines A and B via the LEDs on the front panel.

ENABLE jumper

To first field device

MODBUS line 2

MODBUS line 1

EN.OUT EN.IN

NET 1 NET 2

IN A OUT A

OUT B IN B

LAN

POWER SUPPLY

M S

Power supply line

NET 1

DCM Master

NETH

NET 2

Electronic cards

FDI 1 FDI 2



4.2 Single Station with Redundant Bus In this configuration the system guarantees a network redundancy because when a network fault occurs the field devices are able to isolate the fault and the ring structure permits an alternative path to reach all the devices connected to the bus. For this structure the following LONWORKS rules apply: • The loop length is up to 1400 meters using the recommended cable. • Up to 60 devices (e.g. ICON2000 actuators) can be connected to the loop • to increase the total bus length or the total number of nodes in the loop, it is necessary to use a

repeater or an NCD device. The DCM is equipped with two serial ports to guarantee a redundant connection to the Host.


293DCM500xx where x is the indication of the current setting of the MODBUS communication lines as explained at paragraph 3.1: ‘DCM Manufacturing Code’. The DCM unit is set as follow:

M/S switch on position M

The enable contact EN. IN is kept close by a jumper.

The configuration of the two internal FDI cards is shown in the drawing: the FDI circuit monitored by indication FDI 1 must be configured as NETH node so as to enable the internal termination at one end of the loop. The other FDI circuit, monitored by indication FDI 2, must be configured as NETT node so as to enable the internal termination at the other end of the loop.

NET 1

DCM Master

NETH

NET 2

Electronic cards

FDI 1 FDI 2 NETT

NET 1 NET 2


LONWORKS Interface




The following drawing shows the connections at the rear panel: The serial lines from the Host must be connected to the input ports IN A and IN B of the DCM unit and must be equipped with the necessary terminations as described in paragraph 3.5.4: ‘MODBUS Lines’.

4.2.2 System Behaviour Normal mode the Host is connected to ports A or B of the DCM; the station is active and

communicates with the field, while together with the field units, continuously verifies the loop integrity.

Bus interrupted if the loop integrity check system is enabled, the bus interruption is isolated

from field units that are the closest to the fault, and a correct communication to the still available nodes is recovered. The DCM continues to exchange the available data with the Host.

DCM out of order the DCM cannot communicate with the field. Restarting of DCM the station regains control when it is no longer out of order, i.e. after the

intervention of the operator that removes the fault or once its cause disappears (e.g. power returns after it was missing).

Lines A and B both lines are simultaneously active so the Host can use indifferently either

one: the DCM signals any fault of its serial lines A and B via the LEDs on the front panel.

ENABLE jumper

MODBUS line 2

MODBUS line 1

EN.OUT EN.IN

NET 1 NET 2

IN A OUT A

OUT B IN B

LAN

POWER SUPPLY

M S


Power supply line

From last field device



4.3 Redundant Master with Redundant Bus In this configuration the system ensures the complete redundancy: the network redundancy is achieved because when a network fault occurs the field devices are able to isolate the fault and the loop structure permits an alternative path to reach all the devices connected to the bus. Furthermore the active DCM (Master) is supported by another unit (Slave), ready to take control of the system in case the Master fails. For this structure the following LONWORKS rules apply: • The loop length is up to 1400 meters using the recommended cable. • Up to 60 devices (e.g. ICON2000 actuators) can be connected to the loop • to increase the total bus length or the total number of nodes in the loop, it is necessary to use a

repeater or an NCD device. The two DCM units are equipped with two serial ports that ensure a redundant connection to the Host, which is always connected to the active unit.

4.3.1 DCM Settings In this case the manufacturing code of the DCM will be:

293DCM500xx where x is the indication of the current setting of the MODBUS communication lines as explained at paragraph 3.1: ‘DCM Manufacturing Code’. The DCM units are set as follow:

M/S switch of Master unit is on position M M/S switch of Slave unit is on position S

The Slave EN.OUT port drives the enable EN.IN contact on the Master via a two-poles cable The EN. IN contact of the Slave is kept closed by a jumper.

The configuration of internal FDI cards is shown in the drawing.

NET 1 NET 2


LONWORKS Interface


LAN

NET 1 NET 2


LONWORKS Interface




DCM Master Station: the FDI circuit monitored by indication FDI 1 must be configured as NETH node so as to allow enabling the internal termination at one end of the loop. The other FDI circuit, monitored by indication FDI 2, must be left non-configured with no active termination (both LEDs, L1 and L2 on).

DCM Slave Station: the FDI circuit monitored by indication FDI 1 must be configured as NETT node so as to enable the internal termination at the other end of the loop. The other FDI circuit, monitored by indication FDI 2, must be left non-configured with no active termination (both LEDs, L1 and L2 on).

The following drawing shows the connections between the two stations: no other external circuit is necessary. The two DCM stations must have the same MODBUS station addresses, the serial lines from the Host must be connected to the input ports IN A and IN B of the Slave unit and must be equipped with the necessary terminations as described in paragraph 3.5.4: ‘MODBUS Lines’. The Master ports IN A and IN B are connected to the correspondent OUT A and OUT B ports of the Slave unit. The Slave internally manages the Host lines: when the Slave is in stand-by mode the input lines are switched to the output ports so that the Master is physically connected to the Host; when the Slave is active the input lines are connected to the Slave and the Master connection is cut off.

4.3.1.1 MODBUS Link Cable The serial lines to be connected between the two DCM units in back up (OUT x / IN x) have the following diagram for any communication protocol:

DCM Master

1

2

5

3

4

9 9

1

2

5

3

4DCM Slave

Power supply Power supply

ENABLE jumper

MODBUS line 2

MODBUS line 1

ENABLE link

MODBUS link 2

MODBUS link 1

EN.OUT EN.IN

NET 1 NET 2

IN A OUT A

OUT B IN B

LAN

POWER SUPPLY

M S

To first field device From last field device

DCM MASTER

EN.OUT EN.IN

NET 1 NET 2

IN A OUT A

OUT B IN B

LAN

POWER SUPPLY

M S

DCM SLAVE

NET 1

DCM Master

NETH

NET 2

Electronic cards

FDI 1 FDI 2

NET 1

DCM Slave

NETT

NET 2

Electronic cards

FDI 1 FDI 2



4.3.2 System Behaviour The system behaviour can be described in the following cases: Normal mode the Host is connected to ports A or B of the Slave unit that passes the lines

to the Master; the Master station is active and communicates with the field units. The Slave station does not interrogate the field, but maintains its image of the field updated by means of the LAN connection. The Slave station continuously verifies the correct operation of the Master while the Master checks the Slave.

Bus interrupted if the loop integrity check system is enabled, the bus interruption is isolated

from the closed field units to the failure, and a correct communication with the still reachable nodes is recovered. The DCM continues to exchange the available data with the Host.

Master out of order the Slave station, which controls the correct operation of the Master,

determines that the Master is out of service due to one of the following causes:

communication error on LAN port non-consistent data an explicit message from the Master

When the Slave takes control: Slave switches lines A and B onto itself Slave turns off the local indication Stand by Slave turns on the local indication Run Slave deactivates the Master

The Host recognises its own connection to an active Slave by reading the internal registers of the DCM from the MODBUS interface.

Restoration of the Master the control returns to the Master only after an explicit consent from the

local interface via a command in the Master Slave screen. After receiving the consent, the Slave verifies the good condition of the Master; and waits until the Master is ready to work. Then the Slave returns the control to the Master and goes back to stand-by mode

Slave out of order in case the Slave station is not powered the input MODBUS lines drop to

the output ports so that the Master is physically connected to the Host. The Master station recognises the unavailability of the Slave and sets a specific coil on the MOBUS interface to advise the Host.

Lines A and B both lines are simultaneously active so the Host can use either station

indifferently; the currently active station (either Master or Slave) will reply on the same line. Each station signals any fault of its own A and B serial lines via the LEDs on the front panel.



4.4 Redundant Master with Several Loops With this architecture the system offers a higher level of reliability because, in addition to the network redundancy already seen in the previous paragraph and the back-up function performed by the Slave, the field devices can be grouped into different loops that work independently by means of the additional Output Module. For each loop the same rules of the previous paragraph are still valid. The two DCM units are equipped with two serial ports that ensure a redundant connection to the Host, which is always connected to the active unit.


293DCM510xx where x is the indication of the current setting of the MODBUS Communication Lines as explained at paragraph 3.1: ‘DCM Manufacturing Code’. The DCM units are set as follow:

M/S switch of Master unit is on position M M/S switch of Slave unit is on position S

The Slave EN.OUT port drives the enable EN.IN contact on the Master via a two-poles cable The EN. IN contact of the Slave is kept closed by a jumper.


NET 1 NET 2


LONWORKS Interface


LAN

NET 1 NET 2


LONWORKS Interface


LOOP A

NET 1 NET 2

LOOP B

NET 1 NET 2

LOOP X

NET 1 NET 2

. . . .



The two DCM stations must have the same MODBUS station addresses, the serial lines from the Host must be connected to the input ports IN A and IN B of the Slave unit and must be equipped with the necessary terminations as described in paragraph 3.5.4: ‘MODBUS Lines’. The Master ports IN A and IN B are connected to the correspondent OUT A and OUT B ports of the Slave unit. The Slave internally manages the Host serial lines: when the Slave is in stand-by mode the input lines are switched to the output ports so that the Master is physically connected to the Host; when the Slave is active the input lines are connected to the Slave and the Master connection is cut off. The following drawing shows the connections on the rear panel. Details about MODBUS Link cable are given at paragraph 4.3.1.1 :’MODBUS Link Cable’.

4.4.2 System Behaviour The network can be made of various loops provided the maximum number of nodes is not exceeded. The working principle is the same as in the previous case; therefore the Master and Slave stations work in the same way.


OUTPUT MODULELOOP A LOOP B

NET 1 NET 2

NET 2 NET 1

Power supply

From last field device

To first field device From last field device

NET 1 NET 2

INPOWER SUPPLY

Power supply Power supply

ENABLE jumper

MODBUS line 2

MODBUS line 1

ENABLE link

MODBUS link 2

MODBUS link 1

EN.OUT EN.IN

NET 1 NET 2

IN A OUT A

OUT B IN B

LAN

POWER SUPPLY

M S

DCM MASTER

EN.OUT EN.IN

NET 1 NET 2

IN A OUT A

OUT B IN B

LAN

POWER SUPPLY

M S

DCM SLAVE



5. OPERATOR INTERFACE The operator interface is based on a menu structure where the operator browses via a set of multifunction keys. The operator interface has the following map:

Main

Configuration

Groups List

Nodes List

Supervision

Loop List

Cable List

Dashboard

Memory List

Master Slave

Diagnostics

System

In each screen the bottom line specifies the function assigned to the corresponding softkey within of the current screen; in this way only 4 softkeys can select all the functions implemented in the DCM. The other keys follow these rules: Arrow Up moves the cursor upwards Arrow Down moves the cursor downwards

- displays the next series of available softkeys in the current screen Numeric keys sets a new value in the numeric fields indicated by the cursor 0 sets the Off value in the Boolean fields indicated by the cursor 1 sets the On value in the Boolean fields indicated by the cursor ENTER confirms the edited value and moves the cursor to the next field C exits the current page and returns to the previous page In the home screen it is possible to adjust the contrast of the display. Each pressing of the decimal point “.”key slightly increases the contrast, while each pressing of the minus “-” key slightly decreases the contrast. The messages relevant to the current operations that the DCM sends to the operator are visualized on the second-last line of each screen.

Node Screen



5.1 Main Screen Once the unit is powered up, the DCM opens this main page. This page supplies general information as the current date and time and the software version number. It also shows the plant name to identify the plant that is under DCM control; this indication is read from the configuration file as described in the chapter 6: ‘CONFIGURATION FIILE’. To proceed to the following menu it is necessary to press the relevant numeric key. [1] Configuration moves to the first network configuration and nodes management screen as

described in paragraph 5.2: ‘Networks Configuration and Nodes Management’. [2] Supervision enters the communication network supervision screen as described in paragraph

5.3: ‘Supervision the Communication Network’.

[3] Master Slave enters the Master Slave control system screen as described in paragraph 5.5: ‘Master –Slave Control System’.

[4] Diagnostics enters the diagnostics menu as described in paragraph 5.6: ‘Diagnostics Menu’.

[8] System DCM general configuration settings as described in paragraph 5.7: ‘General

Configuration Settings’.

07/09/2010 09:45:31B I F F I I T A L I A

Diagnostic Communication Master <plant_name>

[1] Configuration [2] Supervision [3] Master Slave [4] Diagnostics [8] System Version: 03_02_



5.2 Network Configuration and Nodes Management From the DCM main screen it is possible to proceed to the Configuration menu by pressing the [1] numeric key. The Configuration menu is the root to configure the field devices connected to the DCM.

5.2.1 Configuration –Groups List The first screen of the Configuration menu shows the groups that compose the network. Among the groups listed in this page the DCM includes two groups by default: ROUTERS it includes the Routers which may be present in the plant; FOREIGN this group is a folder that contains the identification messages (Service Pin) that the DCM

has registered, but which do not correspond to any node known by DCM. For each group the following data are given: id progressive number identifying the group

name name of the group

sts current status of the group: it can assume the following values: CNF all the nodes in the group are correctly configured and connected * at least one of the nodes of the group is no longer in the CNF status DEL all the nodes of group have been cancelled <E> the group is empty

ln line number: the addressing parameter directly managed by the DCM. It corresponds to the

loop index.

sub subnet: addressing parameter directly managed by the DCM. It corresponds to the identification assigned to the group.

The following softkeys are available: Enter enters the selected group and shows the screen with the list of the nodes belonging to the

group.

Groups list id name sts ln. sub description --------------------------------------- [00] GRP-01 CNF 001 010 [01] GRP-02 CNF 001 011 [02] GRP-03 CNF 002 020 [03] GRP-04 CNF 002 021 [04] GRP-05 CNF 003 030 [05] GRP-06 CNF 003 031 [ R] <ROUTERS> CNF [ F] <FOREIGN> <E> Enter Insert Cancel Modify



Insert enables the function to add a new group. Cancel enables the function to delete the selected group and all the nodes included in the group. Modify enables the function to modify the selected group. Cnf.Single configures all the nodes in the selected group that are still unconfigured. See details in the

paragraph 8.2.4.5: ‘Configuration Modes’. Cnf.Nodes configures all the nodes in all groups independently of their current status. See details in

the paragraph 8.2.4.5: ‘Configuration Modes’. Cnf.Uncnf configures all the nodes in all groups that are still non-configured. See details in the

paragraph 8.2.4.5: ‘Configuration Modes’. Wink enables the function to identify the nodes belonging to the selected group: al the nodes in

the group perform the ‘Wink’ function, which normally consists in the winking of the Service LED. ICON and ICON2000 actuators perform the ‘Wink’ function blinking all LED’s on the local operator interface.

Find enables the function to show the group and name by which the device is identified in the

field by the DCM. When this function is enabled the wording “Press Service pin…” appears on the screen. On receiving the acknowledgement message from the node to be identified the name of the group the node belongs to and the name of the device appear on the screen of the DCM.

File enters the screen for the management of the configuration file. From here is it possible to

run several commands to manage the configuration file: Save to save the configuration file in the non-volatile memory and to update the

configuration file; Load to load the configuration file in the working memory after the download of the

configuration file; Format to format the internal Flash memory; GetFlash to retrieve the configuration file from Flash Memory PutFlash to save the configuration file to Flash Memory

Refresh causes the updating of the data area relevant to all groups.



Router List [Root] near far id name position ln# sts ln# sts --------------------------------------- [00] RTR-01 0 CNF 1 CNF [01] RTR-02 1 CNF 0 CNF [02] RTR-03 0 CNF 2 CNF [03] RTR-04 2 CNF 0 CNF [04] RTR-05 0 CNF 3 CNF [05] RTR-06 3 CNF 0 CNF --------------------------------------- Enter Append Cancel Modify

Router: RTR-01 Position: --------------------------------------- NEAR FAR Neuron-id: 000189830100 000230411900 Line id (#): 0 1 Neuron stat.: CNF CNF Subnet list : <- ![10,11, 221] -> [10,11,221] --------------------------------------- Config Child

5.2.2 Configuration – Router List This screen can be reached by selecting the ROUTERS group in the Groups List page and pressing the Enter softkey. It shows all the information relevant to the Routers installed in the Output Module when the network has the redundant structure described at paragraph 4.4: ‘Redundant Master with Several Loops’. Further details on the Routers and about their configuration can be found in the paragraph 8.2.3: ‘Routers Management’. The following data are given for each Router:

id progressive numbers identifying each Router in the list

name name of the Router

for both ‘near’ and ‘far’ sides of the Router

ln# line-id, that is, the identifier of the loop where the Router side is connected sts current status of the node. It can take the following values:

CNF node correctly configured and connected NCO node not communicating NOB not yet configured

The following softkeys are available: Enter enters the specific screen of

the selected Router, where the indications of the Neuron ID relevant to both sides of the Router are available, together with line-id the Router communicates; the status of each side and the list of the subnet connected to them.

From this screen it is possible to configure the current Router or to enter in the Child Router page. The Child Routers are the other Routers that are physically connected beyond the selected Router.



Insert Router Data --------------------------------------- Name: RTR-05 Position: --------------------------------------- NEAR FAR Neuron-id: <waiting> < waiting> Line id (#): 0 0 --------------------------------------- Confirm

Append this enables the function to add a Router to the network. When the Append is enabled a screen appears where the DCM waits for the identification message from the Router to be installed. Once the message is received, the DCM displays the Neuron ID of both sides of the Router. The operator must declare the identifiers of the line-id between which the Router establishes communication. By pressing the Confirm key the operator validates the data entered. The DCM attributes a unique name to the new Router; the operator can modify this name editing the configuration file.

Cancel this enables the function to delete the selected Router. Modify this enables the function to modify the Name and Position parameters of the selected

Router or to change it; in this case the procedure is the same as for function Append. Cnf.Single this configures the selected Router independently of its current status. See details in the

paragraph 8.2.4.5: ‘Configuration Modes’. Cnf. Uncnf configures all Router that are still non-configured. See details in the paragraph 8.2.4.5:

‘Configuration Modes’. Cnf.Nodes this configures all the Routers in the group independently of their current status. See details

in the paragraph 8.2.4.5: ‘Configuration Modes’.



Node list of Group: GRP-02 Line id: 001 Subnet: 011 id name sts Neuron-id type --------------------------------------- [00] ND-02/01 CNF 000197841700 ICONFDI [01] ND-02/02 CNF 010036c7c100 ICONFDI [02] ND-02/03 CNF 000158421600 ICONFDI [03] ND-02/04 CNF 000139373600 ICONFDI [04] ND-02/05 CNF 000138557200 ICONFDI [05] ND-02/06 CNF 000127274500 ICONFDI [06] ND-02/07 CNF 000113936360 ICONFDI [07] ND-02/08 CNF 000125381880 ICONFDI --------------------------------------- Enter Append Cancel Modify

5.2.3 Configuration – Node List This screen shows the list of field devices belonging to the selected group. To reach this page select a group in the Groups List screen and press the Enter softkey. For each node belonging to the group the following data are supplied:

id progressive number identifying each device in the list

name device name (TAG name)

sts current status of the node; it can take the following values:

Node communicating: CNF node is correctly configured and connected TrA the output network terminals of the node are disconnected from the network and

are switched on the line terminator. TrB the input network terminals of the node are disconnected from the network and

are switched on the line terminator. Wai network fault is being detected NCF node no longer configured or in off-line state: new configuration required. NOB node never configured

Node not communicating: NCO configured, but not communicating

Node not present in the node list: DEL node cancelled

Neuron-id 48-bit code identifying the field node

type node type. The DCM manages the following node types: NETH FDI MasterA with advanced research system NETT FDI MasterB with advanced research system NETS FDI Slave with advanced research system ICONFDI ICON2000 actuator VEM VEM generic actuator GENIO General Input / output card and also the following old-type nodes: FDIA FDI configured as MasterA node FDIB FDI configured as MasterB node FDIDis FDI configured as Slave node ICON ICON actuator without on-board FDI More information on these nodes are available in specific documentation.

The following softkeys are available: Enter enters the specific page of the selected node



Insert Node Data --------------------------------------- Name: ND-02/94 Neuron-id: Position : Node Type: ICONFDI --------------------------------------- Confirm Type

Append This enables the function to add a new node to the device list without an external configuration tool. When the Append function is active a new screen appears where the operator must select the type of node to be added by the softkey Type. In this phase the DCM waits for the identification message from the new device to be installed. Once the message is received, the DCM shows the new Neuron ID and waits for the operator to confirm by pressing the Confirm softkey. The DCM assigns a unique name to the new node, which can be modified by the operator. The nodes added remain in the NOB status and must be configured by way of an explicit command.

Cancel this enables the function to cancel the selected node. Modify this enables the function to modify the Name and Position parameters of the selected node

or to substitute the selected node with another node of the same type; in this case the procedure is the same as per the Append function, with the difference that in this case the type of node has already been assigned.

Cnf.Single configures the selected node independently of its current status. Details in the paragraph

8.2.4.5: ‘Configuration Modes’. Cnf.Nodes configures all the nodes in the selected group independently of their current status. Details

in the paragraph 8.2.4.5: ‘Configuration Modes’. Cnf. Uncnf configures all the still non-configured nodes belonging to the selected group. Details in the

paragraph 8.2.4.5: ‘Configuration Modes’. Cnf. PtoP configures the selected node excluding the portion of network beyond the addressed node.

Details in the paragraph 8.2.4.5: ‘Configuration Modes’. Wink this enables the function to identify a node belonging to the group: the selected node

performs the ‘Wink’ function, which normally consists of the winking of the Service LED. The ICON and ICON2000 also flash the LED of the local operator interface for a few seconds.

Find this enables the function to show the name to the field device by which the DCM will

identify it within the group. When this function is enabled the wording ‘Press Service pin…’ appears in the bottom line of the screen; when the acknowledgement message from the node to be identified is received, the DCM screen shows the name given to the device.

Command this enters the screen to send configuration commands to all the nodes of the group.

According to the characteristics of the selected group, a screen appears which lists some of the configuration parameters that are common to the nodes within the group that can be sent to all nodes with a single action (for example, the value of parameter Heartbeat for the nodes type ICONFDI).

Refresh this prompts the update of the data area of the DCM relevant to all the nodes belonging to

the selected group.



Supervision Loop List loop assign map stub Loop Check status --------------------------------------- [01] 046 046 00 active [02] 055 054 01 active [03] 025 025 00 stop [04] [05] [06] [07] [08] --------------------------------------- Dashboard Cable List Mem.List

5.3 Supervision of the Communication Network From the DCM main screen it is possible to enter the Supervision menu by pressing numeric key [2]. Supervision menu offers a set of screens for a complete managing and maintenance of the devices connected in the networks

5.3.1 Supervision – Loop List The first screen of Supervision menu shows the list of the loops that compose the system. For each loop the following data are supplied:

loop progressive number identifying the loop;

assign number of nodes assigned to the loop by the system configuration;

map number of nodes mapped in the loop as result of the automatic procedure for rebuilding the physical wiring sequence;

stub number of nodes connected in ‘stub’ mode – i.e. not belonging to the loop structure – as found by the automatic procedure for rebuilding the physical wiring sequence;

Loop Check status the status of Loop Check Function for the relevant loop. It is summarized by the following indication: ??? Cable List not yet created or NETx not communicating; stop the function is not running; arm’d the function has been launched and the NETx nodes at the ends of the loop are

going to establish valid communication; active the function is operative; working the function is fixing the problem. The status of the Loop Check function also shows an advice when the function has recognised a network interruption and has fixed the problem.

From this screen it is possible to select a specific loop by means of the Arrows Keys and to enter the loop to view either the selected loop or the whole system via the following softkeys: Dashboard proceeds to the synthetic view of the selected loop; Cable List proceeds to the viewing screen of the physical connection sequence of the selected loop; Mem.List proceeds to the viewing screen of the memory allocation sequence of the whole system.



Supervision Dashboard Line id: 2 Loop check active Cabling list Tag name: MOV_125 --------------------------------------- tA ok ok ok ok ok ok ok ok ok ok ok ok al ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok XX ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok ok tB --------------------------------------- Enter PrevLoop NextLoop Cable List

5.3.2 Supervision – Dashboard The Dashboard screen is a very compact way to sketch the status of a selected loop. A single page gathers all the information listed by rows related to the selected loop which may be represented as per the cabling list sequence or by the memory allocation sequence. The status of the Loop Check function for the selected loop is summarized by the following status: stop the function is not running; arm’d the function has been

launched and the two NETx nodes at the ends of the loop are going to establish a valid communication;

active the function is operative; working the function is fixing the problem. fixed a network interruption has occurred and the function has fixed the problem: in this case a

message indicates where the problem is located. Each node is represented by a two-character mark with the following meanings: ok node status CNF node fully operational, correctly configured and connected; tA node status TrA the output network terminals of the node are disconnected from the network

and are switched on the line terminator; tB node status TrB the input network terminals of the node are disconnected from the network

and are switched on the line terminator; wt node status Wai network fault is being detected; XX node status DEL node cancelled from the list by user’s command; B? node status NOB node never configured; C? node status NCF node no longer configured or in off-line state: new configuration required; -- node status NCO configured, but not communicating. Further additional indication are available to highlight a no-operative condition: al node with an application alarm (only for ICON2000); wr node with a warning condition active (only for ICON2000). When the node in the loop but as a “stub” it is represented between the symbols “< >”. The arrows keys move on the nodes mark while the correspondent Tag Name is shown on top of the screen. The following multifunction keys are available: Enter proceeds to the specific screen of the selected node; NextLoop shows the next loop present in the Loop List; PrevLoop shows the previous loop present in the Loop List; Cable List proceeds to the viewing screen of the physical connection sequence; NextPage shows the next page of the selected loop;



Supervision Cabling List Loop check active id name type group sts ln/lp --------------------------------------- [00] ND-01/01 NETH GRP-01 CNF 001 [01] ND-02/01 ICONFDI GRP-02 CNF 001 [02] ND-02/02 ICONFDI GRP-02 CNF 001 [03] ND-02/03 ICONFDI GRP-02 CNF 001 [04] ND-02/04 ICONFDI GRP-02 CNF 001 [05] ND-02/05 ICONFDI GRP-02 CNF 001 [06] ND-02/06 ICONFDI GRP-02 CNF 001 [07] ND-02/07 ICONFDI GRP-02 CNF 001 --------------------------------------- Enter StrCheck StopCheck Dashboard

PrevPage shows the previous page of the selected loop; Phy/Mem toggle the view of the selected loop as per the cabling list sequence or as the memory

allocation sequence.

5.3.3 Supervision – Cable List The Cable List screen displays the field nodes according to the connection sequence in which the field devices were wired. The physical wiring list is built by the DCM by a specific function, which interrogates all the already configured nodes in the network. The following multifunction keys are available: Enter proceeds to the specific screen of the selected node; StrCheck enables the automatic check function for the communication loop integrity; StopCheck disables the check function for the communication loop integrity; Dashboard proceeds to the Dashboard screen of the current loop; Mem.List returns to the visualization of the sequence of allocation memorized; Clear deletes the current wiring sequence; MakeList builds the new physical wiring list



SupervisionMemory List

id name type group sts ln/lp --------------------------------------- [00] ND-01/01 NETH GRP-01 CNF 001 [01] ND-02/01 ICONFDI GRP-02 CNF 001 [02] ND-02/02 ICONFDI GRP-02 CNF 001 [03] ND-02/03 ICONFDI GRP-02 CNF 001 [04] ND-02/04 ICONFDI GRP-02 CNF 001 [05] ND-02/05 ICONFDI GRP-02 CNF 001 [06] ND-02/06 ICONFDI GRP-02 CNF 001 [07] ND-02/07 ICONFDI GRP-02 CNF 001 --------------------------------------- Enter Loop List

5.3.4 Supervision – Memory Allocation List This list shows the sequence of nodes as described in configuration file desfile.csv, corresponding to the sequence of nodes on the MODBUS map. The composition of configuration file desfile.csv affects the order of the DCS interface, but is totally independent of the organization of the plant into groups, or of the physical wiring sequence with which the nodes are connected. The following multifunction keys are available: Enter proceeds to the specific screen of the selected node; Loop List proceeds to the viewing screen of the loops that are composing the system.



FDI Devices ND-01/01 Type NETH Addr Mode 3 Timer Int 250 .4.2.0.8.6.4.2.0 Status 0000000010000000 Warning 0000000000000000 Conn.A Discn.A Conn.B Discn.B

Addr Mode

0 1 2 3

Timer Int 50 0,25 0,50 0,75 1,00

100 0,50 1,00 1,50 2,00

150 0,75 1,50 2,25 3,00

200 1,00 2,00 3,00 4,00

250 1,25 2,50 3,75 5,00

300 1,50 3,00 4,50 6,00

350 1,75 3,50 5,25 7,00

400 2,00 4,00 6,00 8,00

450 2,25 4,50 6,75 9,00

500 2,50 5,00 7,50 10,00

550 2,75 5,50 8,25 11,00

600 3,00 6,00 9,00 12,00

650 3,25 6,50 9,75 13,00

5.4 Devices Check Screen From the pages showing the different list of nodes it is always possible to reach the specific control pages of the connected devices by moving the cursor by means of the Arrow keys and then pressing Enter. These are the different lists of nodes:

Nodes are listed according to their group – see paragraph 5.2.3: ‘Configuration – Node List’; Nodes are listed according to their loop – see paragraph 5.3.2: ‘Supervision – Dashboard’; Physical sequence of wiring - see paragraph 5.3.3: ‘Supervision – Cable List’;

5.4.1 NETH and NETT Nodes From this screen it is possible to control the NETx devices, which, as described at paragraph 8.3.1.2: ‘Enabling the Loop Integrity Chech’, are the core of the communication system integrity as performed by the DCM. Since the integrity check system implemented in NETx nodes uses the FDI cards hardware, it has been maintained the FDI nodes screen. The name of the selected node is shown by its TAG name in the upper part of the screen. The integrity check system has specific commands in the Cable List screen: for this reason, the Enable and Disable commands in this screen must not be used, even though they are active. The screen shows the current configuration of the selected NETx card. The following fields can be modified by the user in case a different configuration should be necessary. Addr Mode Timer Int these two parameters are used to set the

time delay before the communication line is acknowledged as interrupted and the retrieve procedure begins. The following table shows the wait time in seconds, as calculated in function of the two parameters. We recommend always setting a 5-seconds value in order to avoid all false signals of interrupted bus.



Bit Meanings 0 –5 Not used

6 Status of relay B which controls network input side: 0: network not connected -terminator active 1: network connected

7 Status of relay A which controls network output side: 0: network not connected -terminator active 1: network connected

8-13 Not used 14 Loop check function active 15 Loop check function ready

Status This gives the current status of the NETx card by means of the bit structure shown in the table (bit numbering is right to left):

Warning not used

The following function keys are available: Conn.A this manually connects the A side (bus out) of the selected node to the network Discon.A this manually disconnects the A side (bus out) of the selected node from the network Conn.B this manually connects the B side (bus in) of the selected node to the network Discon.B this manually disconnects the B side (bus in) of the selected node from the network Ena.All do not use for NETx node - this enables the FDI function on all the nodes in the loop Dis.All do not use for NETx node - this disables the FDI function on all the nodes in the loop Ena.Node do not use for NETx node - this enables the FDI function on the selected node Dis.Node do not use for NETx node - this disables the FDI function on the selected node Send this sends the new configuration to the selected node

A B

T T

to field from field



ICON Main Screen ND-02/01 Alarm Summary Off Opening Off Open Limit Off Torque 0 % Closing Off Position 0 % Close Limit On Open Lock Off Monitor On Close Lock Off ESD active Off Remote On Enable Off Local Off Setpoint 0 % Off Off Fbk Delay 1 s Setup Off Dead Band 1.5 % Factory Off ESD command Off Send Open Close Stop

5.4.2 ICONFDI Nodes This is the starting point for a series of pages for the control of the ICON2000 actuators connected to the network. Its TAG in the upper portion of the screen indicates the ICON2000 actuator. The screen shows the detail of the current status of the selected actuator, and in particular: Alarm Summary On when there is a diagnostics indication Torque current torque Position current position Open Lock On when an Open Lock command has been sent by the relevant softkey

(correspondent function on ICON2000 shall be enabled) Close Lock On when a Close Lock command has been sent by the relevant softkey

(correspondent function on ICON2000 shall be enabled) ESD active On when the ICON2000 actuator performs an ESD command Opening On when the actuator moves in opening direction Open Limit On when the actuator reaches the full open position Closing On when the actuator moves in closing direction Close Limit On when the actuator reaches the full closed position Monitor On when the actuator is available for remote control Remote On when the selector is in REMOTE position Local On when the selector is in LOCAL position Off On when the selector is in OFF position Setup On when a configuration procedure is running from actuator local operator interface Factory Always Off ESD command On when an ESD command has been sent by means of the relevant softkey

For INCHING actuators: Enable when set to On, this enables the ICON2000 to follow the Set Point. This command

is effective only if the Positioner function has been enabled in the addressed ICON2000 actuator.

Set Point current Set Point Dead Band Dead Band value Fbk Delay delay before following a new Set Point variation



The available multi-function keys are as follows: Send to send to the actuator the parameters of the Inching setting Open to send the Open command Close to send the Close command Stop to send the Stop command Open Lock to send the Open Lock command Close Lock to send the Close Lock command ESD to send the ESD command Diagnostic to send the diagnostics page Maint/NP to send the Maintenance and Nameplate page Config. to send the Configuration page Fdi to send the actuator FDI control page



ICON Alarm Screen ND-02/01 1/2 Over Torque Contactor Failure Mid Off K1 Off Closing Off K2 Off Opening Off Phase Motor Reversed Off Stalled Off Loss Off Too Hot Off Sensor Failure Other Failures Position Off Pushbutton Off Torque Off PWR Failure Off Reset

5.4.2.1 Diagnostic Screen From the Diagnostic screen it is possible to visualize all messages from the selected actuator: the diagnostic messages are collected in two pages, Alarms and Warnings. Shifting from one page to the other is by the Arrow keys. When a field value is set as On, the relevant fault has been detected. The following multifunction key is available: Reset this command cause a refresh of the internal data in the selected actuator NOTE: The ICON2000 LONWORKS interface has the same communication profile as the ICON model so as to ensure the total compatibility between the two models. It is thus possible to substitute an ICON with an ICON2000 without changing either the DCM or the DCS software in use. This important feature means that the data structures relevant to the Alarms and Warnings have maintained the same shape they used to have in the ICON model, even though the two models have different internal circuits and electronics. The Diagnostic screen reflects the differences; The following tables show the references to tables 10.1 and 10.2 (pages 84-85) of document ICON2000 Instruction Manual (MAN618), where the meaning of the diagnostics messages is explained. WARNING DCM Screen ICON 2000 Description Torque Near Max Mid Not applicable: always Off Torque Near Max Closing See Table 10.2 'High torque in closing' Torque Near Max Opening See Table 10.2 'High torque in opening Local Stop Depressed in Remote The STOP push-button was pressed while the selector was in REMOTE

position. The signal will be reset on the next valid command. Card Temperature Exceeded See Table 10.2 ' Internal Temperature' Battery Low Not applicable: always Off



ALARM DCM Screen ICON 2000 description Over Torque Mid Not applicable: always Off Over Torque Closing See Table 10.1 'High torque in closing’ Over Torque Opening See Table 10.1 'High torque in opening' Phase Reversed Not applicable: always Off Phase Loss Phase error (third phase missing).

See Table 10.1 'Phase loss' Sensor Failure Position See Table 10.1 ‘Position sensor’ Sensor Failure Torque Not applicable: always Off Contactor Failure K1 See Table 10.1 'K1 Contactor’ Contactor Failure K2 See Table 10.1 'K2 Contactor’ Motor Stalled See Table 10.1 'Jammed valve in opening' and 'Jammed valve in closing’

Motor Too Hot See Table 10.1 Motor Thermostat Other Failure: Push-button See Table 10.1 Hardware fault Other Failure: PWR Failure Voltage. See Table 10.1 ‘Main voltage close to limit'

NOTE: ‘Not Applicable’ means that the relevant diagnostics message is not present in the ICON2000 LONWORKS interface. All other diagnostics indications listed in Table 10.1 of document ICON2000 Instruction Manual (MAN618) and not categorized in the ALARM data structure are stored by the DCM in the ‘Alarm Summary’ indication.



ICON Nameplate ND-02/01 2/2 Power Supply Valve Type Three Phase On Quarter T Off Single Phase Off Multi T On Nameplate Actuator Size ICON#20/180-144 Serial Number 042528E05001 Motor Supply 410V 3ph5 0Hz Hardware Rev. A Software Rev. 0.53 Nominal Torque 180 Actuator RPM 600 Config. Date 08 04 2005

>

ICON Maintenance ND-02/01 1/2 Maintenance Information Commissioning Date 18 05 2003 Maintenance Date 01 05 2008 Peak Torque 0 % @ 0 % Average Torque 47 % Number of Cycles 504 Torque Calibration Parameters CCW @ 100% 16 CCW @ 40% 80 CW @ 40% 176 CW @ 100% 240 Send

5.4.2.2 Maintenance / Nameplate Screen From the Maintenance screen it is possible to visualize all the information relevant to the selected actuator: Commissioning Date date of actuator first installation on field Maintenance Date date of next scheduled maintenance Peak Torque max. measured torque and position where this measure was reached (only ICON) Average Torque average torque of actuator operations (only ICON) Number of Cycles current number contactor starts Torque Calibration Parameters reference values for the ICON actuator torque sensor.

ICON2000 actuator has a different Torque sensing circuit and these parameters are no longer used.

The following multi-function key is available: Send this sends the new commissioning or scheduled maintenance date to the selected actuator. By means of the arrow keys it is possible to shift to the Nameplate screen. From the Nameplate screen it is possible to visualize the information memorized in the selected actuator.



ICON Configuration ND-02/01 2/3 ESD Action 0 0> Drive Stop On 1> Position Off 0 % 4> Drive Open Off 5> Drive Close Off Bypass Trq Alarm Off Speed Control Enable Off On Time 1 s Stop Opening 100 % Off Time 0 s Start Closing 100 % High Turns Off Send

ICON Configuration ND-02/01 3/3 Variables List Close Trq Limit 75 % Open Trq Limit 75 % Jammed Valve 2 s Trq Bypass 5 % Trq Band 4 % Instant Reversal Dly 0.8 s Deadband 1.5 % Feedback Dly 1 s Heartbeat 60 s Position Sensitivity 1 % Torque Sensitivity 5 % Send

ICON Configuration ND-02/01 1/3 Position Torque Close Limit On Off Open Limit On Off Local Display On Off Clockwise to Close On Correct Phase Error On Clamp Local Display On Send

5.4.2.3 Configuration Screen The Configuration screen comprises a series of pages from where it is possible to visualize or modify the ICON2000 setting parameters. If one of the setting parameters is modified, the actuator behaviour will change accordingly. It is thus necessary to be very careful in modifying such values. For the ICON2000 the following parameters are read-only: Close Limit Open Limit Clockwise to Close The following parameters are not used by the ICON2000: Local Display always On Correct Phase Error always On Clamp Local Display always On High Turns always Off The following multi-function key is available: Send this sends the new

configuration to the selected actuator.



FDI Devices ND-02/01 Type ICONFDI Addr Mode 1 Timer Int 150 .4.2.0.8.6.4.2.0 Status 0000000011010000 Warning 0000000000000000 Conn.A Discn.A Conn.B Discn.B

Bit Meaning 0 -5 Reserved

6 Status of relay B which controls network input side: 0: network not connected -terminator active 1: network connected

7 Status of relay A which controls network output side: 0: network not connected -terminator active 1: network connected

8 Reserved 9 Reserved

10-15 Used for indications on actuator status

5.4.2.4 ICON2000 - On-board FDI Screen From this page it is possible to check the status of the on-board line terminations implemented on the LONWORKS interface of ICON2000 actuator. The terminations are managed by the Loop Integrity Check function after it has been activated on the relevant loop. The screen shows a set of information; some of them are no longer used with the current Loop Integrity Check function. Addr Mode not used.

Timer Int not used. Status This gives the current

status of the terminations by means of the following bit structure (bit numbering is right to left):

Warning not used. The following multi-function keys are available: Conn.A this manually connects the A side (bus out) of the selected node to the network Discon.A this manually disconnects the A side (bus out) of the selected node from the network Conn.B this manually connects the B side (bus in) of the selected node to the network Discon.B this manually disconnects the B side (bus in) of the selected node from the network Ena.All do not use - this enables the FDI function on all the nodes in the loop Dis.All do not use - this disables the FDI function on all the nodes in the loop Ena.Node do not use - this enables the FDI function on the selected node Dis.Node do not use - this disables the FDI function on the selected node Send this sends the new configuration to the selected node

A B

T T

to field from field



VEM Control ND-03/01 Open limit Off Close limit On Command Off Var. Config. 60 Send

5.4.3 VEM Nodes From this page it is possible to control a generic device by means of 2 physical digital inputs and one physical digital output as it has been implemented in VEM device. It is suitable for a generic actuator (either hydraulic or pneumatic), and to obtain information on the current status of the two limit switches. Open limit current status of opening limit switch Close limit current status of closing limit switch Command enabling command for the actuator control system Var. Config number of seconds for the retransmission of the current limit values The following multi-function key is available: Send this sends the new command to the selected VEM



GEN.IO Control ND-03/01 Digital in: 1 Off 5 Off 2 Off 6 Off 3 Off 7 Off 4 Off 8 Off Analogue in: 1 45.18 % 2 22.16 % Analogue out: 1 25.00 % 2 100 % Digital out: 1 Off 3 Off 2 Off 4 Off Send Config

GENIO Digital configuration ND-03/01 Filter H(0)/L(1) H(0)/L(1) DI1 0 0 DO1 0 DI2 0 0 DO2 0 DI3 0 0 DO3 0 DI4 0 0 DO4 0 DI5 0 0 DI6 0 0 DI7 0 0 DI8 0 0 Heartbeat: 100 s Digital out disable: Off Send Analog Cfg

5.4.4 GEN.I/O Nodes From this page it is possible to control a generic device by means of 8 physical digital inputs, 2 physical analogue inputs, 4 physical digital output and 2 physical analogue output as it has been implemented in GEN.I/O device. Digital in 1-8 value of the relevant

physical digital inputs

Analogue in 1-2 value of the relevant physical analogue inputs

Analogue out 1-2 value to be set for the relevant physical digital output

Digital out 1-4 value to be set for the relevant physical analogue output The following multi-function keys are available: Send this sends the new command to the selected GEN.I/O unit Config this moves to the GEN.I/O Configuration screen The first configuration screen is related to the configuration of digital signals. In the Filter column it is possible to set a time filter on each digital input channel. Levels of filter set are:

0 no filter 1 50msec filter 2 100 msec filter 3 150 msec filter

In the H(0)/L(1) column it is possible to define the active state of each digital channel.

0 signal active ‘High’ i.e. logical status 1 makes the N.O. contact to close.

1 signal active ‘Low’ i.e. logical status 1 makes the N.O. contact to open.

Heartbeat number of seconds for the retransmission of the current value of the input

signals. If it set as 0, the network variables will only be transmitted when the variation of analogue signals is higher than sensitivity.

Digital out disable when set to Off, the GEN.I/O card does not send any analogue signals; when set

to On the digital outputs are ignored and the analogue output are enabled.



GENIO Analogue configuration ND-03/01 Type --> (0) 4-20mA AI1 0 (1) 0-20mA AI2 0 (2) 2-10V AO1 0 (3) 0-10V AO2 0 Heartbeat: 100 s Analogue input sensitivity: 1 Analogue out enables: On Send

The second configuration screen is related to the configuration of analogue signals. In the Type column it is possible to define the type of analogue signal among the following:

0 4-20mA signal 1 0-20mA signal 2 2-10V signal 3 0-10V signal

Analogue out sensitivity sensitivity value of the analogue signals causing the emission of network

variables when the Heartbeat value is set as 0. Analogue out enable when set to Off, the GEN.I/O card does not send any analogue signals; when set

to On the digital outputs are ignored and the analogue output are enabled.



Master Slave Status ---------------------------------------- Local Remote Data LanTm Request: 0 0 0 3 Status: 2 8 Queue 0% Fdi/Rtr: 0 0 CnfSize: 3710 3710 CnfDate: 02:04:2008 02:04:2008 CnfTime: 14:22:37 14:22:37 Ena. In: 0 Nodes : 93 0 NwFdi:0 Cuts:0 / 0 Fdi A/B: 4 0 4 0 Routers: 8 0 8 0 --------------------------------------- Release Get

5.5 Master – Slave Control System From the DCM main screen it is possible to enter the Master Slave control menu of two back-up units. This is done by pressing numeric key [3].

5.5.1 Master Slave This page is useful for the supervision of the Master Slave system between the DCM units of a redundant system. The data related to the local unit are listed in column Local, while column Remote is related to the other DCM connected via LAN. The information in this page is very technical and may not interest common users. It is reported below the explanation of the most common data.

Request status of information request (Service only) at Local and Remote station Status code indicating the status of the Master Slave check at Local and Remote station: the two

more important states are: 2 unit is in back-up state 8 unit has the control and is running

Fdi/Rtr number of FDI cards or Routers that are not communicating at Local and Remote station. LanTm count down of the traffic on the LAN network: normally it counts quickly from 20 to 0.

When the counter remains steady at 0 it means that the LAN communication has stopped. Queue utilization rate of the fieldbus commands queue: it gives an indication of the working load

of the DCM. In heavy load condition this figure should remain to a constant value different from 0%. If it reaches the value 99% the DCM will reply a ‘busy’ error code to the MODBUS interrogation.

CnfSize dimension of configuration file in bytes at Local and Remote station CnfData date of configuration file at Local and Remote station CnfTime time of configuration file at Local and Remote station Ena. In status of EN.IN. input: 0 = enabled Nodes valid on the active DCM

index of the node currently being examined by the control task of the active DCM number of nodes found in error

Cuts loop integrity summary valid on the active DCM: number of network interruptions detected number of network interruptions fixed



Fdi A/B Status of FDI cards connected at the two ends of loop directly linked to the active DCM index of NET_H currently being examined by the DCM number of NET_H found in error index of NET_T currently being examined by the DCM number of NET_T found in error

Routers Status of Routers connected at the two ends of loop directly linked to the active DCM

index of nodes in the Routers at near side currently being examined by the DCM number of nodes in the Routers at near side found in error index of nodes in the Routers at far side currently being examined by the DCM number of nodes in the Routers at far side found in error

Each Router is considered as composed of two nodes and for this reason the number of nodes shown is twice the number of physical Routers.

The following multi-function keys are available: Release to pass control to the other unit

Get to takes control from the other unit.



Modbus ReportLine 1 2 3 LAN Channel A B * L Station N. 1 1 1 1 # of msg 0 0 0 0 Slave msg 0 0 0 0 # characters 0 0 0 0 exception 0 0 0 0 CRC errors 0 0 0 0 wrong msg 0 0 0 0 wrong frame 0 0 0 0 Service TestLed TestDOut Logics

5.6 Diagnostics Menu From the DCM main screen it is possible to enter the diagnostics menu by pressing numeric key [4].

5.6.1 Diagnostics The diagnostics page displays the statistics relevant to the MODBUS communication lines. Data are listed for each serial line, which is identified by its channel name.

Station N. the MODBUS addressed assigned to each serial line

# of msg number of MODBUS messages received at the line port

Slave msg number of received MODBUS messages which were addressed to the line port

# of characters number of characters received in the latest message

CRC errors number of messages received with a CRC error

wrong msg number of messages received with a wrong command

wrong frame number of messages received with wrong data.

The following multi-function key is available: Service reserved service page TestLed this runs an automatic function, only available to the ADMINISTRATOR, causing the

LEDs on the DCM front panel to flash for 3 seconds TestDOut this runs an automatic function, only available to the ADMINISTRATOR, causing the four

relay outputs available on the DCM to be progressively enabled. Logics shows the current values of digital inputs and digital outputs connected to the DCM and the

status of the GCx definition.



[email protected]

System Utilisation Statistics ---------------------------------------- Ident: 03_02_02_10 Current Login: OBSERVER Used Free ROM (bytes): 197404 268104691 RAM (bytes): 908220 3285059 DB (bytes) 127448 Nodes/Routers allocated: 63 / 16 Battery: On --------------------------------------- Login Logout Password Clock

5.7 General Configuration Settings The Configuration Menu can be reached from the main screen by pressing the [8] numeric key. From this menu it is possible to configure the DCM and the User Login.

5.7.1 System This is the main configuration screen of the DCM. The following general data are indicated: Ident full software revision identifier Current Login current login level ROM ROM memory used and available RAM RAM memory used and available DB internal Data Base dimension Nodes/Routers allocated number of nodes for which memory is allocated Battery indication of current status of Alkaline batteries: when it is set to Off is

highly recommended to replace the batteries following the procedure described in paragraph: 8.7: ‘Replacing Batteries’.

The following softkeys are available: Login performs system login Logout exits the present login level and returns to OBSERVER level Password sets access passwords Clock set the clock and calendar Info moves in the general information screen Ethernet sets the IP address of the Ethernet network Modbus sets the MODBUS interface parameters Mb.Diag enters the diagnostics screen for MODBUS communications Parameters reserved service page



User Login ---------------------------------------- Current Login: OBSERVER User : OPERATOR Password: **************** ---------------------------------------- User Login!

Password Management ---------------------------------------- Current Login: ADMINISTRATOR User : MAINTENANCE Password: ---------------------------------------- User Change

5.7.2 Login This is the screen where the operator is identified by indicating the user ID and password. In order to be identified the operator must first select the user by way of softkey User, then enter the correct password and press the Login softkey.

5.7.3 Password The ADMINISTRATOR can modify the access passwords of all system users. In order to assign a new password the user must be selected by way of softkey User, then the new password must be entered and softkey Change pressed.



System Clock Setting ---------------------------------------- 07/09/2010 10:11:45 DST:2 Date (dd/mm/yyyy): 07 / 09 / 2010 Time (hh:mm): 10 : 11 DST (Enable/Disable): On SCREEN SAVER Setting time (Sec): 200 Timer (Sec): 112 ---------------------------------------- Set D.&T.

5.7.4 Clock In the Clock screen the ADMINISTRATOR can set the current date and time, and the time for display turnoff. DST Daylight Saving Time: current status of the Daylight Saving Time function

when it is enable. Possible values are: 1: DST active, i.e. during summer time 2: DST not active 3: DST function disabled.

Date (dd/mm/yyyy) to set current date Time (hh:mm) to set current time. Seconds are set at 00 on new settings by way of Date &

Time softkeys DST (Enable/Disable) to Enable or Disable the DST function SCREEN SAVER Setting time (Sec) set time in second (from 15 to 255) before the automatic backlight display

turn-off. Backlighting will turn off after the indicated time has elapsed unless an operation is performed on the keyboard. The display will turn on again by pressing any key.

Timer (Sec) remaining time in second before display turn-off. The following softkey is available: Set D.&T. this key enables the set date and time values. Set date and time are also sent

to the back-up DCM.



Ethernet Settings ---------------------------------------- IP address: 192 . 168 . 200 . 249 Subnet mask: 255 . 255 . 255 . 000 ----------------------------------------

General Plant Information ---------------------------------------- Biffi Ack: Project : Plant : Config file date: 02:04:2008#14:22:37 Map DCM3 mode: 0 Domain value (0..99): 0 ----------------------------------------

5.7.5 Info This page provides some information related to the plant where the DCM is installed. The information is read from the section info of the configuration file as described in paragraph 6.1: ‘File header [info]’.

5.7.6 Ethernet The ADMINISTRATOR can set the DCM IP address the DCM uses on the Ethernet network available at LAN port. As general rule the Master unit has an odd IP address (default 192.168.200.249) and the Slave an even IP address (default 192.168.200.248). Basically this line is used for the communication between Master and Slave related to system redundancy and to connect external PC for maintenance purpose. On this line it is also active a MODBUS TCP driver to allow a supplementary MODBUS channel. It is important to point out that this MODBUS TCP channel uses the same IP address defined in this screen for the unit.



Lines Modbus Setting ---------------------------------------- Line Slave Address Chan 1 1 A TCP Off 2 1 B 3 1 * LAN 1 L Line1 Line2 Line3 LAN

Lines Modbus Setting ---------------------------------------- Line Slave Address Chan 1 1 C TCP On 2 1 B 3 1 D LAN 1 L Line1 Line2 Line3 LAN

5.7.7 MODBUS Lines Setting This screen shows the current setting of the MODBUS lines and allows the ADMINISTRATOR to change the parameters relevant to each line. In the column Slave Address it is possible to set a MODBUS slave address to each line and by means of the field TCP set the current association between physical lines and channel types. As shown in the figures when TCP is disabled Line 1 and Line 2 are associated to the serial channels A and B and Line 3 is not active. When TCP is enabled Line 2 remains associated to the serial channel B, Line 1 and Line 3 are associated to the Ethernet channels C and D. In both cases it is always available an Ethernet channels L associated to the LAN line. With the relevant softkey it is possible to enter in the specific screen to set the communication parameters of the channel currently associated to the physical line.



Serial Port Setting – Line 1 – Chan A---------------------------------------- Baud rate Parity Stop-Bit N.Bit 38400 0 1 8 Set Chan

Ethernet Setting – Line 3 – Chan D ---------------------------------------- MAC : 00:41:58:80:36:E0 IP address: 192 . 168. 200 . 249 Subnet mask: 255 . 255 . 255 . 000 Port: 502 Set Chan

5.7.7.1 MODBUS RTU Channels Channel A and B implement MODBUS RTU communications. The ADMINISTRATOR can set the following parameters: Baud rate selected baud rate. The

speed of each port can be set as 300, 600, 1200, 4800, 9600, 19200, 38400 or 57600.

Parity 0 None 1 Odd 2 Even

Stop_Bit number of stop bits

N.Bit number of bits per character

In order to change the settings it is necessary to move the cursor to the field to be modified and enter the new value. The parameter setting it is possible at the DCM station with the control: it will propagate the same port setting to the back up unit. It will maintain the same communication line between DCS and DCM system independently from what unit, Master or Save, has the control.

5.7.7.2 MODBUS TCP Channels Channel C and D implement MODBUS TCP communications For the selected channel is given the MAC address and the Port number. The ADMINISTRATOR can set the following parameters: IP address

Subnet mask

In order to change the settings it is necessary to move the cursor to the field to be modified and enter the new value. The parameter setting it is possible at the DCM station with the control: it will propagate the same port setting to the back up unit. It will maintain the same communication line between DCS and DCM system independently from what unit, Master or Save, has the control.



6. CONFIGURATION FILE The DCM configuration file describes the composition of the network controlled by the DCM and the MODBUS map structure. All the details about the network are collected in the following section:

info: contains the general information about the plant topology: defines the network structure, with the definition of Routers groups: declares the groups defined within the network nodetype: defines the information transferred to the MODBUS interface for each node type devices: defines the field devices, the Tag names and their position on the MODBUS

interface free_mod_var optional section to define MODBUS addresses when ‘Function wise’ map model

has been chosen cablelist: report the physical sequence wiring of the field devices.

The configuration file is an ASCII file compiled with the following simple rules:

all the fields in the record are separated by one of the following characters: ‘=’ (equal) for ini file style - default - ’;’ (semicolon) for csv file style ‘,’ (comma);

each line must be terminated by one of the following characters <CR><LF> as in MS DOS text file standard (Enter key) only <CR> only <LF> as in Unix text file standard;

semicolons at the end of the line are not considered as a new fields; characters <Space> and <TAB> introduced between the records of a line to enhance legibility are

ignored; empty lines are ignored; sections must respect the given order and are identified by the labels :

[section-name]

6.1 File header [info] The configuration file header consists of the following lines of the section info:

[info] Name=BIFFI ITALIA srl ack= <Acknowledge_number_string> string of 30 characters project= <Project_name_string> string of 30 characters plant= <Plant_identification_string> string of 30 characters date= <Date_string> string of 30 characters domain=0 LONWORKS domain identification

These information in the header file are collected in the DCM screen System | Info Furthermore the section info collects the data about the meaning associated to the four local Digital Outputs available on the DCM and about the composition of the MODBUS map.



6.1.1 MODBUS map structure definition The DCM MODBUS map is divided in two different memory areas: Internal Data that collect data relevant to DCM status and communication status of the field

devices connected to DCM. Field Image that collect data relevant to the field devices connected to DCM. As detailed in

Appendix A1: ‘Structure of the MODBUS Interface’, this area may be configured in different memory models depending on the characteristics of customer’s control system

MODBUS map ‘Function wise’ where controls and signals of the field

devices are collected in banks of homogeneous types (e.g.: all the commands Open_Valve grouped in a bank of DO area; all signals Valve_Fully_Open grouped in a bank of DI area, etc);

MODBUS map ‘Object wise’ where controls and signals are grouped per

device (e.g.: all the commands of the first device followed by all the commands of the second and so on).

The selection of the MODBUS map in ‘Function wise’ or ‘Object wise’ influences the allocation of the ‘Internal Data’ and of the banks of the ‘Field Image’ at different addresses. The structure of the MODBUS map is defined by means of the following statements in the info section:

modbus_di=<addr_internal_data>,<addr_bank0>,<addr_bank1>, . . . modbus_do=<addr_internal_data>,<addr_bank0>,<addr_bank1>, . . . modbus_ai=<addr_internal_data>,<addr_bank0>,<addr_bank1>, . . . modbus_ao=<addr_internal_data>,<addr_bank0>,<addr_bank1>, . . .

where for each MODBUS area is defined the starting addresses of the banks that are composing the area. For each MODBUS area is possible to define up to 16 banks. By definition the first address is related to the internal data zone while the next fields are related to the different banks that are composing the MODBUS area. ‘Function wise’ model

modbus_di=10000,<addr_bank0>,<addr_bank1>, . . . modbus_do=10000,<addr_bank0>,<addr_bank1>, . . . modbus_ai=10000,<addr_bank0>,<addr_bank1>, . . . modbus_ao=10000,<addr_bank0>,<addr_bank1>, . . .

‘Object wise’ model

modbus_di=0,1000 modbus_do=0,1000 modbus_ai=0,3000 modbus_ao=0,3000

The ‘Internal Data’ may be defined in different formats whatever MODBUS map has been selected.

Internal Data in ‘Extended mode’ Internal Data in ‘Packed mode’ Internal Data in ‘Legacy mode’

The following scheme may clarify the different maps structures.



‘Function wise’ model [info] . . . . modbus_di=10001,1,101,201 modbus_do=10001,1.101,201 modbus_ai=10001,1 modbus_ao=10001,1

‘Object wise’ model

[info] . . . . modbus_di=0,1000 modbus_do=0,1000 modbus_ai=0,3000 modbus_ao=0,3000

DI area addr 1 __ addr. 2 __ addr. 3 __ . . .

Bank 0

addr 101 __ addr. 102 __ addr. 103 __ . . .

Bank 1 addr 201 __ addr. 202 __ addr,.203 __ . . .

Bank 2addr 10001 addr 10002 addr 10003 . . .

Externded Packed Legacy

DO area Bank 0 Bank 1 Bank 2

Field Image

AI area Bank 0

AO area Bank 0

__ __ __

__ __ __

__ __ __

addr. 1 __ addr. 2 __ addr. 3 __ . . .

addr 101 __ addr. 102 __ addr. 103 __ . . .

addr 201 __ addr. 202 __ addr..203 __ . . .

addr 10001 addr 10002 addr 10003 . . .

__ __ __

__ __ __

__ __ __


addr 1 __ addr. 2 __ addr. 3 __ . . .

addr 1 __ addr. 2 __ addr. 3 __ . . .

Internal data zone


Field Image

addr 0 addr 1 addr 2 . . .

Internal data zoneExternded Packed Legacy

DO area

AI area

AO area

__ __ __

__ __ __

__ __ __

addr 1000 __ addr. 1001 __ addr. 1002 __ . . .


__ __ __

__ __ __

__ __ __


addr 3000 __ addr. 3001 __ addr. 3002 __ . . .

addr 3000 __ addr. 3001 __ addr. 3002 __ . . .

MODBUS MAP

DCM MODBUS MAP



The composition of DCM Field Image at MODBUS interface is defined by the sections nodetype, devices and free_mod_var as described above, while the structure of the Internal Data is given by the definitions in the section info whatever bank has been addressed for the Internal Data zone. Internal Data in MODBUS DI area is composed of a section for internal status of DCM and a section that reports the communication status of the devices connected to the DCM. When the digital inputs is set to 1 means that the relevant node in not communicating. This second section may be defined in the following three different modes. Internal Data zone in ‘Legacy mode’

dcmr3_mode=0 extended_map=0

In ‘Legacy mode’ the Internal Data reserves one digital input to each node as they are declared in the section devices to indicate the current communication status of that device. ‘Legacy mode’ is the structure of the MODBUS map available on the DCM equipped with software revision 3.02.00.xx or older. Internal Data zone in ‘Packed mode’


In ‘Packed mode’ the Internal Data reserves two digital inputs for each Router as they are declared in the section topology corresponding to the ‘Near side’ and to the ‘Far side’ of the Router and then one digital input to each node as they are declared in the section devices. Internal Data zone in ‘Extended mode’


‘Extended mode’ is similar to ‘Packet mode’ but in this case the communication status of Router, node type NET_X and node type ICON are allocated in separate blocks of contiguous digital inputs. In this way a future expansion of the loop will not affect the previous MODBUS map structure, but will cause the adding in the relevant section of the new communication indication. More details and schemes are available in Appendix A1: ‘Structure of the MODBUS Interface’.

6.2 Section [topology] This section describes the communication network architecture. When no Routers are present, the section is left empty:

[topology] Instead, when the communication network structure uses Routers, each line in this section will have the following information:

Router Name: name of the Router ‘RTR-xx’; Router Loop-id near: the identification of the line between the DCM and the near side of the

router; Router Loop-id far the identification of the line connected at the far side of the router. In

case of a simple router structure it corresponds to the loop identification;

Neuron ID of the Near side Neuron ID of the Far side Router Description optional description string



Each line in the section describes one single Router; more Routers can be added to the section. In the following example four Routers are configured to define a system with two loops:

[topology] RTR-01=0,1,001079034600,001079035700, RTR-03=0,2,001904184000,000239036800, RTR-02=1,0,001077423800,000230448300, RTR-04=2,0,002017443300,001904686500,

In case that the field network structure does not describe a ‘closed loop’, but the network is rather e ‘bus structure’, it is necessary to add in the last line of the section [topology] the statement:

Loop_bus_like= ... followed by the identification of the loops that are ‘bus’ connected. As example a network structure as shown in the figure, where loop 2 is connected as a ‘bus’ structure will be declared:

Loop_bus_like=2

6.3 Section [groups] This section includes the description of the groups of devices in the network. Each line in this section describes one group; the section can define more groups. Each record within this section has the following fields:

<group_name>=<loop_id>,<subnet>,<description> where: <group_name> name of the group; <loop_id> identification of the line to which the group belong; <subnet> identification of the subnet associated to the group; <description> 9-character optional description string

Output Module

Loop B

S M

Loop A

Output Module

Loop2

S M

Loop1

DCM SLAVE

High speed bus

DCM MASTER

Loop id 0

High speed bus

Loop id 0

NET_H

Loop B

Loop-id 2

RTR-03

RTR-04

NET_T

NET_H

Loop A

Loop-id 1

RTR-01

RTR-02

NET_T



Example:

[groups] NetL01=1,10 GRP-01=1,11 GRP-02=1,12

By default the group that collect the nodes NET_H and NET_T of each loop is called NetLxx, where xx is the loop number.

6.4 Section [nodetype] This section allows to define the variables that will be available at the Field Image area for all node types. The section is built as a set of subsection, one for each node type. The first line of the subsection is the node declaration:

<node_id>=<input_var>,<output_var>,<node_name> It defines for the specific node type the number of variables connected to the MODBUS interface: <node_id> node identifier, code number corresponding to the DCM internal code:

node_id node_name Description 3 FDIA FDI configured as Master A node 4 FDIB FDI configured as Master B node 5 FDIDis FDI configured as Slave node 8 ICON ICON actuator without on-board FDI 9 ICONFDI ICON or ICON2000 actuator

10 GENIO General Input / Output card 11 VEM Generic VEM actuator 13 NETH MasterA FDI with advance research system 14 NETT MasterB FDI with advance research system 15 NETS Slave FDI with advance research system

<input_var> number of input variables that will be transmitted by the node to the DCM; <output_var> number of output variables that will be transmitted to the node from the DCM; <node_name> node name corresponding to the node_id. After the node declaration it follows the list of the communication elements belonging to the node that will be connected to the MODBUS interface. For each element the definition is given by a line with the following format: <nv#>,<def_mask>,<scaling_L1>,<scaling_L2>,[<scaling_L3>,]<name> <nv#> 1-60 network variable number that identify the communication element in the

node by means of its nv index; -1 definition of a ‘dummy_0’ element. The correspondent element in the

MODBUS interface map will be read as ‘0’; -2 definition of a ‘dummy_1’ element. The correspondent element in the

MODBUS interface map will be read as ‘1’ in case of Coil or Discrete Input or at value 65535 (0xffff) in case of Holding Register or Input Register.



<def_mask> mask that defines the correspondence in the MODBUS map of the selected communication element.

for a real communication element (i.e.: the value declared in <nv#>

corresponds to a network variable element of the node):

b7-b4 bank address from 0 to 15 b3-b2 command set group: 0 = no command set assigned;

1-3 = number of command set group. When DCS sets a Coil to 1 or an Holding Register to a ‘not 0’ value, the other Coils or Holding Register of the node belonging to the same group are automatically reset to 0.

b1 command persistency: 0 = permanent: DCS take care of set and reset the Coil or the

Holding Register; 1 = transient: when DCS set the Coil to 1 or an Holding Register to a

‘not 0’ value, DCM reset it after issue the relevant command. b0 direction: 0 = MODBUS command 1 = MODBUS input signal

mask byte structure to define a dummy element (i.e. the value declared in <nv#> is -1 or -2)

b7-b4 bank address from 0 to 15 b3-b2 not used b1 dummy type: 0 = dummy bit (Coil or Discrete Input) 1 = dummy register b0 direction: 0 = MODBUS command 1 = MODBUS input signal

b7 b6 b5 b4 b3 b2 b1 b0

b7 b6 b5 b4 b3 b2 b1 b0

b7 b6 b5 b4 b3 b2 b1 b0

b7 b6 b5 b4 b3 b2 b1 b0

b7 b6 b5 b4 b3 b2 b1 b0

b7 b6 b5 b4 b3 b2 b1 b0

b7 b6 b5 b4 b3 b2 b1 b0

b7 b6 b5 b4 b3 b2 b1 b0



<scaling_L1> conversion for the analogue values to the MODBUS interface on Line 1 associated either to Channel A or Channel C: 0 no conversion: the analogue value varies between 0 (0%) and 20000 (100%); 8 8-bit scaling: the analogue value varies between 0 (0%) and 255 (100%); 9 9-bit scaling: the analogue value varies between 0 (0%) and 511 (100%); 10 10-bit scaling: the analogue value varies between 0 (0%) and 1023 (100%); 11 11-bit scaling: the analogue value varies between 0 (0%) and 2047 (100%); 12 12-bit scaling: the analogue value varies between 0 (0%) and 4095 (100%).

<scaling_L2> conversion for the analogue values to the MODBUS interface on Line 2 associated to Channel B: 0 no conversion: the analogue value varies between 0 (0%) and 20000 (100%); 8 8-bit scaling: the analogue value varies between 0 (0%) and 255 (100%); 9 9-bit scaling: the analogue value varies between 0 (0%) and 511 (100%); 10 10-bit scaling: the analogue value varies between 0 (0%) and 1023 (100%); 11 11-bit scaling: the analogue value varies between 0 (0%) and 2047 (100%); 12 12-bit scaling: the analogue value varies between 0 (0%) and 4095 (100%).

<scaling_L3> conversion for the analogue values to the MODBUS interface on Line 3 associated to Channel C (valid only if the DCM is equipped with CPU model 493CPU3000 and Channel C has been enabled): 0 no conversion: the analogue value varies between 0 (0%) and 20000 (100%); 8 8-bit scaling: the analogue value varies between 0 (0%) and 255 (100%); 9 9-bit scaling: the analogue value varies between 0 (0%) and 511 (100%); 10 10-bit scaling: the analogue value varies between 0 (0%) and 1023 (100%); 11 11-bit scaling: the analogue value varies between 0 (0%) and 2047 (100%); 12 12-bit scaling: the analogue value varies between 0 (0%) and 4095 (100%).

<name> description of the variable: it is used during the creation of the MODBUS map documentation file.

The section nodetype is unique in the desfile.csv file. The definitions of each node type connected to the DCM shall be present in the section. The ‘Factor of conversion for the analogue value’ field shall be set as 0 for the non- analogue variables. Dummy elements shall not belong to a command set group. The sequence of the elements in the Field Image map of the MODBUS interface will follow the order of the <nv#> list given for each node type and will be repeated for each device listed in the section devices. Further the above ‘automatic’ MODBUS map generation, it possible also to assign other communication elements in the MODBUS map at a specific address as described in paragraph 6.6: ‘Section [free_mod_var]’.



Examples: MODBUS map ‘Object wise’: example of the description of the ICONFDI node. The analogue variables related to current position and setpoint are scaled on 12 bits.

[nodetype] 9=5,7,ICONFDI 0=0,0,0,Drive Open 1=0,0,0,Drive Close 2=0,0,0,Stop 6=0,12,12,Setpoint 7=1,0,0,Valve Open 8=1,0,0,Valve Closed 9=1,0,0,Opening 10=1,0,0,Closing 11=1,0,0,Monitor Relay 12=1,0,0,Alarm Active 13=1,12,12,Position 31=0,0,0,Inching Mode

MODBUS map relevant to two actuators will result as shown in the following scheme:

DI area addr 1000 MOV01_Valve Open addr. 1001 MOV01_Valve Closed addr. 1002 MOV01_Opening addr. 1003 MOV01_Closing addr. 1004 MOV01_Monitor Relay addr. 1005 MOV01_Alarm Active addr 1006 MOV02_Valve Open addr. 1007 MOV02_Valve Closed addr. 1008 MOV02_Opening addr. 1009 MOV02_Closing addr. 1010 MOV02_Monitor Relay addr. 1011 MOV02_Alarm Active . . .

Field Image

DO area

AI area

AO area

addr 1000 MOV01_Drive Open addr. 1001 MOV01_ Drive Close addr. 1002 MOV01_Stop addr. 1003 MOV01_Inching Mode addr 1004 MOV02_ Drive Open addr. 1005 MOV02_ Drive Close addr. 1006 MOV02_Stop addr. 1007 MOV02_Inching Mode . . .

addr 3000 MOV01_Position addr. 3001 MOV02_Position . . .

addr 3000 MOV01_Setpoint addr. 3001 MOV02_Setpoint . . .



MODBUS map ‘Function wise’: example of the description of the ICONFDI node. The analogue variables related to current position and set point are scaled on 12 bits.

[nodetype] 9=5,7,ICONFDI 0=0x06,0,0,Drive Open // DO_Bank0; cmd set grp 1; transient 1=0x16,0,0,Drive Close // DO_Bank1; cmd set grp 1; transient 31=0x24,0,0,Inching Mode // DO_Bank2; cmd set grp 1; permanent 7=0x01,0,0,Valve Open // DI_Bank0 8=0x11,0,0,Valve Closed // DI_Bank1 11=0x21,0,0,Monitor Relay // DI_Bank2 6=0x00,12,12,Set Point // AO_Bank0; port A & B 12 bits scaling 13=0x01,12,12,Position // AI_Bank0; port A & B 12 bits scaling

MODBUS map relevant to two actuators will result as shown in the following scheme:

DI area addr 1 MOV01_Valve Open addr. 2 MOV02_Valve Open . . . . . .

Bank 0 addr 101 MOV01_Valve Closed addr. 102 MOV02_Valve Closed . . . . . .

Bank 1addr 201 MOV01_MonitorRelay addr. 202 MOV02_MonitorRelay . . . . . .

Bank 2


Field Image

AI area Bank 0

AO area Bank 0

addr. 1 MOV01_Drive Open addr. 2 MOV02_Drive Open . . . . . .

addr 101 MOV01_Drive Close addr. 102 MOV02_Drive Close . . . . . .

addr 201 MOV01_Inch. Mode addr. 202 MOV02_Inch. Mode . . . . . .

addr 1 MOV01_Position addr. 2 MOV02_Position . . . . . .

addr 1 MOV01_Setpoint addr. 2 MOV02_Setpoint . . . . . .



6.5 Section [devices] This section includes the description of all the nodes included in the network. Each line represents a device and the order in which they are listed defines the sequence in the MODBUS interface. Each record within this section has the following fields:

<tag_name>=<node_id>,<Neuron_id>,<group_name>,<description> where: <tag_name> 8-character node name as it is referenced in DCM; <node_id> node identifier, code number corresponding to the DCM internal code and identifying

the code used in section nodetype; <Neuron_id> unique 48-bit identifier associated to the node used by LONWORKS protocol; <group_name> name of the group to which the actuator belongs to, corresponding to the group name as

defined in section groups; <description> 9-character optional description string. Example:

[devices] L1_01=13,000871010500, NetL01, N100B=9,000933172100,GRP-01, N105B=9,00a264710300,GRP-02, N107B=9,000611162000,GRP-02, N300B=9,000933170700,GRP-01, N506A=9,000933169900,GRP-01, N507A=9,00a264719500,GRP-01, L1_02=14,000871010500, NetL01,



6.6 Section [free_mod_var] This section is available only when the MODBUS map structure has been defined as ‘Function wise’. In this case it is possible to assign a selected communication element of a field device to a specific MODBUS address. In case that no free association are requested this section is not present at all, otherwise each record within this section has the following fields:

<tag_name>=<nv#>,<bank_address>,<offset> where: <tag_name> 8-character node name as it is referenced in DCM; <nv#> 1-60 network variable number that identify the communication element in the node

that has to be placed ‘manually’ in the MODBUS map. <bank_address> mask byte structure for bank addressing

b7-b4 bank address from 0 to 15 b3-b0 not used

<offset> relative address from bank starting address where to place the communication element.

The selection of the MODBUS area where the bank is defined is managed by the DCM depending on the type of nv# selected.

Each communication data maintains the attribute defined in [nodetype] section. As example if an analogue data need a “scaling” conversion it will be defined in [nodetype] section where it will be assigned to a “dummy” memory bank. The definition in [free_mod_var] will place the analogue data in the requested memory bank at the defined offset maintaining the defined “scaling” factor. Examples:

[free_mod_var] N509_B1=13,0x00,370 /* Variable nv#13=Position of device N509_B1 is allocated on

bank0 of AI area at offset 370 */ Since the banks definition and the associations table use a limited data structure in DCM software, a practical mode to calculate the number of associations still available is to consider that the number of banks defined in section info added to the rows defined in this section shall not exceed 64.

b7 b6 b5 b4 b3 b2 b1 b0

b7 b6 b5 b4 b3 b2 b1 b0



6.7 Section [cablelist] In this section is stored the wiring sequence of the node connected to the DCM. If the sequence is unknown the section will be empty:

[cablelist]

When the DCM re-builds the physical wiring list, this section is completed and stored in the desfile.csv It is also possible to manually compile this section if the physical wiring sequence is known. Each record in this section has the following fields:

<loop_id>=<ref>,<tag_name>,L<loop_id>-<num> where: <loop_id> n>0 identification of the loop to which the node is connected;

-1 node connected as ‘stub’, i.e. the node is not able to participate to the ‘Loop integrity check’ function.

<ref> reference to the line of the section devices where the node is declared; <tag_name> 8-character node name as it is defined in section devices; <num> position in the physical sequence. Example:

[cablelist] 1=0,L1_01,L01-000 1=4,N300B,L01-001 1=1,N100B,L01-002 1=5,N506A,L01-003 1=6,N507A,L01-004 1=3,N107B,L01-005 1=2,N105B,L01-006 1=7,L1_02,L01-007



6.8 Local Input/Output Configuration As seen at paragraph 3.5.6: ‘I/O Interface’ the DCM is equipped with physical input/output channels that correspond to input signals and coils on the MODBUS map to allow DCS to read the status of physical inputs or to drive the physical outputs. It is also possible to use the hardwired channels for special purpose functions out of MODBUS control as described in the next paragraphs.

6.8.1 Local DO configuration In the info section it is possible to write an ‘equation’ for each physical digital output to define the condition that set to 1 the relevant output contact. It may be useful to drive locally hardwired circuit like a Common Fault Contact. The digital outputs driven by equation are no more available at MODBUS interface. The equations may contains the following operators: <!> correspond to the logical operator .NOT. <&> correspond to the logical operator .AND. <|> correspond to the logical operator .OR. and the following conditions: Off The physical output is driven only by the status of the coil in the MODBUS map PwrON DCM is correctly powered SysOK DCM has successfully configured its internal fieldbus interface (LED ‘System OK’ on) BatLow Internal Battery low UPSLow UPS battery low LanEr LAN communication between Master and Slave is not working (LED ‘LAN’ on) FieldEr Almost one field node is not communicating (ICON2000, VEM, GENIO etc) RtrEr Almost one Router is not communicating NetEr Almost one NET_H or NET_T is not communicating CutAct In a redundant fieldbus structure a network fault has been recognised and the system

has fixed it (LED ‘Field Error’ blinking) in1, in2, in3, in4 Status of the relevant physical inputs of the DCM The equations are executed from left to right without priority, e.g.:

<digital_out> = <first_condition> | <second_condition> & <third_condition>

Example:

[info] . . . . do1 = PrwON & SysOK // DO contact is closed until DCM works fine do3 = !BatLow // DO contact is closed until Battery is good do4 = FieldEr | RtrEr | NetEr // DO contact closes in case of communication problem

First operation

Second operation



6.8.2 Local DI configuration In the info section it is possible to write an ‘equation’ to force a specific command to the field devices by means of physical digital inputs. The command is defined exploiting the ‘command set group’ definition as seen in paragraph 6.4: ‘Section [nodetype]’ and creating a GCx definition in the info section. An example may clarify. It is requested a single Emergency Push Button to send an ESD command to all the actuators in the loop.

General scheme is shown in the figure: input #1 is connected to the general ESD Emergency Push Button.

In the nodetype section of the DCM configuration file the ESD command of ICON actuator will be associated to the command set group coded 0x01.

[nodetype] 9=8,11,ICONFDI 0=0,0,0,Drive Open 1=0,0,0,Drive Close 2=0,0,0,Stop 3=0,0,0,Open Interlock 4=0,0,0,Close Interlock 5=0x04,0,0,ESD //0x04 = 0b0000 0100 6=0,0,0,Set Point 7=1,0,0,Valve Open 8=1,0,0,Valve Closed 9=1,0,0,Opening 10=1,0,0,Closing 11=1,0,0,Monitor Relay 12=1,0,0,Alarm Active 13=1,0,0,Position 14=1,0,0,Torque 15=1,0,0,Actuator State 16=1,0,0,Warning 17=1,0,0,Alarm 31=0,0,0,Inching Mode

In the info section of the DCM configuration file the following ‘equation’ links the physical input #1 to the command set group :

[info] . . . . . . GC1=in1

When the logic equation changes from FALSE to TRUE (i.e. in this case the input is closed) the command set group 01 is activated and an ESD command is sent to all the actuators. The command is maintained until the contact is kept close.

If more variables of the same device type are declared as belonging to the same command set group, them will be set together. In the logic equation shall be listed all the events and operators already defined for DO Configuration. While the logic equation is TRUE, MODBUS lines cannot overwrite the coils corresponding to the commands under control of the active command set group. The permanence of the command to the field devices generated by equation follows the rules given by bit1 in the definition mask:

b1=0 permanent: command is active until equation is TRUE an in the above example; b1=1 transient: after the command is issued it will be automatically reset.

Next transition TRUE to FALSE of the logic equation clears the correspondent coils in the MODBUS map and the control of them returns to MODBUS lines.

NET 1 NET 2

DCM

2 1 IN. #1

+ Vext

- Vext

4 3 IN. #2

6 5 IN. #3

8 7 IN. #4

ESD



7. EXTERNAL OPERATOR INTERFACE The DCM managing function as configuration transfer and remote terminal can be executed on an external PC just connecting it to DCM via Ethernet line. Software upgrade is available via serial line using a PC connected to CONF port. Furthermore it is possible to exploit the field image data kept by DCM by means of the Maintenance Station DCMi.

PC Windows 95/98; Windows 2000/XP/NT

Ethernet Line Configuration transfer ftp <IPaddress> Remote terminal HyperTerminal

Maintenance Station DCMi

LAN

NET 1 NET 2


LONWORKS Interface


LAN

NET 1 NET 2


LONWORKS Interface




7.1 Setting the PC Ethernet Port In order to establish a connection between the PC and the DCM unit via the Ethernet line, it is necessary to correctly set the TCP/IP protocol configuration on the PC.

Open the Properties page of the network connection via LAN.

Select the TCP/IP protocol line relevant to the network card being used.

Click on the Properties page to open the panel TCP/IP properties.

Indicate a specific IP address, as shown; it have to match with the IP address configured on the DCM.



7.2 Configuration File Transfer Via the Ethernet line, the DCM can establish an ftp connection to a connected PC (port 21). Through this channel it is possible to manage the DCM configuration file transfer by the following procedure. The default system configuration file name is desfile.csv.

1. Connect the DCM which has the control (Run led blinking) to the PC by means of the Ethernet cable supplied with the DCM. In case of redundant DCM system (Master/Slave) the other unit with the Stan-by led blinking receives the configuration file directly from the Master upon completion of configuration file uploading.

2. Open an MS-DOS shell on the PC.

3. Enter the following command at the prompt:

ftp <IPaddress> where: <IPaddress> is the IP address of the unit to be upgraded:

- default Master: 192.168.200.249 - default Slave: 192.168.200.248

4. After established FTP connection the authentication procedure asks for user identification and

password; they are the same as the ones used to access to Local Interface.

5. At ftp prompt enter the command line:

<command> <source_file> [<destination_file>] <command> The following commands are available:

dir to visualize the list of files stored in the DCM memory; get to retrieves a file from the DCM memory; put to sends a file to the system; the back-up unit automatically acquires it; bye to close the session.

6. From the operator interface of the DCM enter in Group list screen and launch File | Load command: DCM reads the configuration file and prepares its internal memory for the new configuration. At the end the configuration file is passed to the Stand-by unit connected.

Example of connection with retrieval of file desfile.csv:

C:\>ftp 192.168.200.249 Connesso a 192.168.200.249. 220 FTP-York ver 1.01. Please enter your user name Utente (192.168.200.249:(none)): ADM 331 User name Ok, give your password Password: 230 User logged in, proceed ftp> get desfile.csv desfile_last.csv 200 Command okay 150 File status ok; about to open data connection 226 Closing data connection ftp: 1627 bytes received in 0,94secondi 1,74Kbyte/sec) ftp> bye 221 Service closing control connection C:\>



7.3 Remote Terminal

7.3.1 HyperTerminal Session The HyperTerminal connection is enabled from the PC ‘Connections’, by establishing a new connection with the following characteristics: A window appears on the display reproducing the DCM screens on the local interface: Surfing the various pages if the operator interface is via the numeric keys (main menus) and function keys (F1, F2, F3 and F4) dynamically associated to the softkeys in the other screens. In some PCs the function keys are not active: in this case pressing the key corresponding to the flashing letter in the softkey name enables the softkey function.



7.4 Software Update via Serial Line StreamUpd is a program that allow to the user the capability to update the application software on the DCM by transferring the new code stored in the given files *.lx . The program will detect the maximum speed sustained by the line and perform the program update in the minim time possible. To use StreamUpd it is necessary to connect the serial cable supplied with DCM between COM1 port of the PC and the port CONF of the DCM to update; in case of Redundant DCM system the operation must be repeated for both the stations. By Open in File menu select the .lx file that store the new software to download. By Go in Transfer menu the program gets ready to start: it is necessary to power off and on the DCM to force the station in receiving mode and start the data transfer. When the download is completed the DCM restart with the new software. Details on the function procedure of software update are given in paragraph 8.6: ‘Software Download on DCM’.



7.5 Maintenance Station Maintenance Station DCMi is a Windows based program that collect the data coming from the ICON2000 actuator connected to the DCM and shows them in convenient graphical displays. In the following generic scheme it is shown the connection of the Maintenance Station to the DCM system. Among the several functions available at Maintenance Station are remarkable the following: • Multilanguage support; • Schematic representation of the devices that are composing the plant and visual sketch of cabling

sequence; • Reading of set-up, nameplate and configuration data straight from field devices and representation of

these data in specific screens; • Acquisition of Position vs. Torque curves and their memorization; • Event and Alarm log; • Password protected enhanced functions to change set-up data or command sending; • Statistical reports based on historical data; • Data available for other users inside the plant Local Area Network.

DCS DCMi Maintenance Station

Ethernet Switch MODBUS lines

HBU Unit (optional)


NET 1 NET 2


LONWORKS Interface


LAN

NET 1 NET 2


LONWORKS Interface


LOOP A

NET 1 NET 2

LOOP B

NET 1 NET 2

LOOP X

NET 1 NET 2

. . . .



Details are available in the document ‘Maintenance Station DCMi ‘ User’s Manual R.0.0



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8. FUNCTIONAL PROCEDURES

8.1 Get the DCM working

Connect the field bus, according to the implemented bus structure, as described in chapter

4: ‘SETTING FOR TYPICAL APPLICATION’

Turn the DCM unit on

Check communication with field devices following the instructions at

5.4: ‘Devices Check Screen’

Does the Configuration File

exist?

Configure the DCM following instructions at 8.2.2: ‘Configurating a Network with the

Configuration File’

Follow the procedures described in 8.2.1:’Creating a New Network without

Configuration File’

Loop structure? Activate the loop integrity function as described in

paragraph 8.3: ‘Activation of Loop Integrity Check’

Is DCS present? Verify the DCM serial line set by checking its

manufacturing code, as described in paragraph 3.1: ‘DCM Manufacturing Code’

Refer to paragraph 3.5.4: ‘MODBUS Lines’ for what concerns cable specifications for various

serial line types

Refer to paragraph 5.7.7: ‘Modbus Lines Setting’ for the setting of communication parameters

Check the voltage of the electric supply and move the voltage selector to the correct position, as described in paragraph 3.5.1: ‘Input Supply’

Is DCS present? Yes

Yes

Yes

No

Yes

No

No

No



8.2 Network Configuration and Nodes Management

8.2.1 Creating a New Network without Configuration File Before to start a new plant composed of a DCM and a set of actuators it is necessary proceed with a system configuration. It is advisable to verify first that no other configuration file is already present in the DCM. In this event it is necessary reset DCM as explained in paragraph 8.5: ‘Resetting the DCM’. At the beginning the screen Groups list is empty: the DCM does not communicate with any of the field devices.

From the Groups list screen select a group and enter the selected one by pressing softkey Enter

Log in as ADMINISTRATOR

Leave all MODBUS communication lines non-connected, since the DCS interface is not active yet

Power up the back-up unit, if present, so that the configuration is automatically saved on both units

From the Groups list screen, by pressing softkey Insert, add the groups that compose the plant

Are Routers present?

No

Yes

Add the node by way of the Append function seen at paragraph 5.2.3: ‘Configuration – Node List’ (see note 1).

NETH and NETT-type nodes must belong to a dedicated group

Repeat for all nodes in all groups

To change the tag name that the DCM automatically assigns to the nodes when they are added to the list, read the configuration file as explained at paragraph 7.2: ‘Configuration File Transfer’. This file can be elaborated by an ASCII text editor

like Notepad

Transfer the modified configuration file onto the DCM

Load the configuration file by command Load from the File menu in the Groups list screen

Run the general configuration function by command Cnf.Nodes from Groups list screen

Proceed with Router configuration as described at paragraph 8.2.3: ‘Routers Management’



Note 1: if an Hyper Terminal Session in open as seen in paragraph 7.3.1, the Operator Interface can exploit the PC keyboard; in this way the valve tag name shall be given while the node is appended.

8.2.2 Configurating a Network with the Configuration File If the configuration file is already available, the configuration procedure is extremely simple. It is advisable to verify first that no other configuration file is already present in the DCM. In this event it is necessary first reset DCM as explained in paragraph 8.5: ‘Resetting the DCM’ Since the Neuron IDs are already in the configuration file, the operation will proceed automatically and with no interruptions to the last node in the network. Warning: a cable interruption in any portion of the loop may cause an un-proper configuration

result. Before to proceed with a configuration operation of a node in a specific loop it is

recommended to verify first the good communication status of the two nodes NET_H and NET_T at both end of the loop.

In case it is required to configure the whole network, it is recommended first to configure the group of the NET-x nodes. After the two nodes are configured and communicating it is possible to proceed with the other groups.

Transfer the configuration file as explained at paragraph 7.2: ‘Configuration File Transfer’..

Log in to the system as ADMINISTRATOR

Load the memory file by command Load from the Filemenu in the Groups list screen

Run the general configuration function by command Cnf.Nodes from screen Groups list



8.2.2.1 Load Command Error Codes During the execution of command File | Load in the Groups list screen is run, the configuration file is loaded from memory, and the data structures for the management of the nodes in the network are built. In order to perform these operations the configuration files undergoes a formal check. In case of error, a message reports the following error codes so that the operator can make the necessary corrections. More details on the composition of the configuration file can be found at paragraph 6: ‘CONFIGURATION FILE’.

Error code Description

1 Configuration file not found

2 topology headline not found

3 Error in a line of section topology

4 Max Routers number exceeded (max 36)

5 groups headline not found

6 One of the groups has subnet 0

7 Error in a line of section groups

8 Max groups number exceeded (max 99)

9 nodetype headline not found

10 Error in a line of section nodetype

11 Number of device types declared exceed maximum number (max 9)

12 devices headline not found

13 Error in a line of section devices

14 Max nodes number exceeded (max 300)

15 cablelist headline not found

16 Error in a line of section cablelist

17 Elements in the physical list exceed the elements defined in section devices

18 Neuron ID not unique

19 Number of variables defined for node exceeded (max 63)

20 Too many elements declared: no more memory available for network image

21 Max number of node defined in a Group (max 126)

22 DO# not valid in digital output configuration equation

23 Max. variables in logic function equation

24 Syntax error

25 nv index exceeds max nv number

26 Group does not exist

27 Logic function error

28 Device type not found

29 Error in MODBUS bank declaration

30 Error of declaration in section free_mod_var

31 Not valid type definition for MODBUS bank

32 MODBUS bank does not exist

33 Max banks number exceeded (max 64)

34 Error in section free_mod_var: node does not exist

35 GC# not valid in Group Command configuration equation



8.2.3 Routers Management Routers are devices that establish communication between two ‘media’ with different electric characteristics, both having the same LONWORKS protocol. The DCM manages the Routers used within the Output Module; these devices connect a 1,25Mbps network to a 78kbps network. Routers also manage the addressing of packets towards their destination subnets: that is, they reduce network traffic to the only packets that must reach the groups defined within the loop.

In order to be configured, Routers must know the portions of the plant where they belong to: this information is supplied by the line-id. As show in the figure, the high-speed bus portion always has a line-id =0, while the loops in the field respectively have line-id 1 and 2; more possible loops would have progressively numbered line-ids. In order to manage the addressing of packets, the DCM configures the Routers in accordance to special ‘routing tables’ defining which subnets (i.e. which groups) are defined in the connected line-id. In the configuration of a network with several loops the Routers must acquire the ‘routing tables’ before the configuration of the actuators and of the other nodes is made. The recommended sequence of operations to be performed in case of a system composed of several loops is as follow:

1. define the entire system structure editing the configuration files and defining the groups; 2. download the configuration file to the DCM Master; 3. from DCM Master configure the Routers first; 4. append and configure the field nodes in the appropriate group. Once a new group has been appended to an already configured network it is necessary to run a new configuration of the group ROUTERS in order to update the ‘routing table’ of all the Routers installed.

8.2.3.1 Router Fault If a Router does not work properly, the DCM manages this occurrence so as to ensure the maximum reliability of the plant. If the non-working Router is connected to the active DCM, control is switched to the back-up unit. Instead, if the non-working Router is connected to the back-up DCM, the DCM signals the Slave DCM is no longer available.

NET_H NET_T NET_H NET_T

High speed bus

LOOP A LOOP B

Line-id 1

RTR-01

DCM MASTER DCM SLAVE

RTR-03 RTR-04

Line-id 2

Line id 0

RTR-02



8.2.4 Nodes Management

8.2.4.1 Cancelling a Node from a Group This operation eliminates all reference to a node in the DCM list. If the Cancel command is sent to a device that DCM shows as CNF (i.e.: it is in good communication status), also the bus interface of the device is cleared to factory default.

8.2.4.2 Cancelling a Group This operation eliminates all reference to all the nodes in the group to be deleted. All the bus interfaces of the devices that are defined in the group to be deleted and are shown in DCM screen as CNF (i.e.: they are in good communication status), will be cleared to factory default.


Enter the group with the node to be deleted

In the Node list screen, select the node to be deleted

Run the function Cancel. The device is deleted and reset to default values.

The status of the device in the list is changed to DEL and its Neuron ID to ffffffffffff


Enter the Groups list screen and select the group to be deleted

Run the function Cancel. All the devices in the group will be cancelled and reset

to their default values. The status of the deleted actuators will be changed to

DEL and their Neuron IDs to ffffffffffff. The status of the deleted group will be changed to DEL



8.2.4.3 Replacing a Node in the Network In order to replace a devices in the network it is necessary to electrically connect a new device in place of the faulty one and to perform the following procedure. Warning: The bus interface of the replacement must be cleared BEFORE to activate it in the new

network. If the replacement is not a new spare from factory, but it comes from another loop, it is necessary to run a Cancel procedure before to detach it from the origin loop.

8.2.4.4 Adding a Node to a Network In order to add a new node to an existing network it is necessary to electrically connect the new device and perform the following procedure. Warning: The bus interface of the new node must be cleared BEFORE to activate it in the network.

If the new node is not a new spare from factory, but it comes from another loop, it is necessary to run a Cancel procedure before to detach it from the origin loop.


Enter the group with the node to be replaced

In screen Node list, select the node to be replaced

Run the function Modify. When requested send the acknowledgement message

(Service pin) from the new device. The new device is identified and its Neuron ID appears

in the screen in the place of the previous one.

Press Confirm to validate the change

Perform the configuration function of the new node by command Cnf.Single from the Node list screen


Enter the group where the new device must be added

Run the function Append.When requested send the acknowledgement message (Service pin) from the new device.

The device will be added at the end of the list. If an Hyper Terminal Session is open as seen in paragraph 7.3.1 the valve tag name shall be given

while the node is appended.

Perform the configuration function of the new node by command Cnf.Single from the Node list screen



8.2.4.5 Configuration Modes Node configuration is a crucial point of a network commissioning and maintenance. The operator may choose the more appropriate configuration procedure to the different situations among a set of configuration methods available at DCM configuration screens as described in paragraph 5.2: ‘Network Configuration and Node Management’ and here below summarized:

DCM screen Line selected Softkey Description

Group List ROUTERS

Cnf.Sing.

It is launched a new configuration sequence of all routers listed in ROUTERS group that are not yet been configured and that are in a good communication condition.

Cnf.Nodes

A new configuration sequence of all routers and nodes listed in all the defined groups is launched independently from their current communication state.

Cnf.Uncnf The configuration sequence is sent to all routers and nodes listed in all the defined groups that are not yet been configured.

Group List <Group_name>

Cnf.Sing.

It is launched a new configuration sequence of all nodes listed in the selected group that are not yet been configured and that are in a good communication condition.

Cnf.Nodes

A new configuration sequence of all routers and nodes listed in all the groups is launched independently from their current communication condition.

Cnf.Uncnf The configuration sequence is sent to all routers and nodes listed in all the groups that are not yet been configured.

Router List <Router_name>

Cnf.Sing.

A new configuration command of the router <Router_name> is launched independently from its current communication state.

Cnf.Nodes

A new configuration sequence for all the routers listed in ROUTERS group is launched independently from the current communication state of each router.

Cnf.Uncnf The configuration sequence is sent to all router listed in ROUTERS group that are not yet been configured.

Node List of Group: <Group_name> <Node_name>

Cnf.Sing. A new configuration command of the node <Node_name> is launched independently from its current communication state.

Cnf.Nodes

A new configuration sequence for all the nodes belonging to the group is launched independently from the current communication state of each node.

Cnf.Uncnf The configuration sequence is sent to the nodes listed in the current group that are not yet been configured.

Cnf.PtoP

The selected node <Node_name> is configured independently from its current communication state following the sequence below described.



The commands launched by the softkeys Cnf.Sing., Cnf.Nodes and Cnf.Uncnf execute the configuration task while the other nodes already configured in the loop continue their communications. The methods associated to softkeys Cnf.Nodes and Cnf.Uncnf can execute the whole configuration in automatic way without any interruption until the end of the task. Warning: A configuration command of a node which is not in good communication condition

(e.g. it is reported as NCO) will not lead to a successful configured status. Most probably at the end the node will be put in the “Not Configured” state (NCF. It is recommended first to investigate on the reasons that are causing the NCO state. Possible point of investigation are: 1. Network fault between DCM and node; 2. Network terminations not in place: this may produce reflection; 3. High noise on the communication network.

Configuration Peer-to-Peer is a further method available for nodes that implement FDI hardware like ICONFDI or NET_x. By the softkey Cnf.PtoP it is performed the following sequence: 1. DCM verifies if the selected node is physically connected and ready to communicate.

If the nodes is not ready it is set to NCF status and the procedure stops. If the nodes is ready the procedure goes to next step.

2. DCM sends to the selected node a Side A disconnect command to cut the network beyond the node. 3. DCM verifies if the selected node is still ready to communicate.

If the nodes is not ready it means that it has been connected reversed: an advice on the screen appears and operator has these two possibilities: o Fix the node connection and press the softkey Continue: the procedure restart at step 1. o Abort the procedure by key [C]. The procedure stops, but the operator has to restore the

network by local command at the operator interface of the selected node. If the nodes is ready the procedure goes to next step.

4. DCM configures the selected node as per Cnf.Sing. method while the portion of the network beyond

the node remains apart. At the end the procedure goes to the next step. 5. DCM sends to the selected node a Side A connect command to restore the network beyond the node.



8.3 Activation of Loop Integrity Check

8.3.1.1 Rebuilding the Physical Wiring List The physical wiring list is part of configuration file desfile.csv and it is generally not known during plant commissioning. In this case, after downloading the desfile.csv file and performing the system configuration, the Cable List screen will be empty. To get the system working it is mandatory to follow these rules:

1. Every loop must starts from a NET_H node and ends at a NET_T node; NET_H and NET_T nodes are located inside the DCM stations in case of single loop structure or included n the Output Module in case of multiple loop structure.

2. Fieldbus network enters in first actuator ICON2000v4 at terminal A1, A2; 3. Fieldbus network exits from first actuator ICON2000v4 at terminal A4, A5; 4. Steps 2 and 3 are repeated for all ICON2000v4 actuators in the loop.

It is necessary use both input and output terminals of ICON2000v4 actuators because the Loop check function uses the relays mounted in the LONWORKS interface card inside the actuator By means of softkey MakeList the DCM starts the procedure for rebuilding the physical wiring sequence by interrogating all configured nodes. Before to start the reconstruction of the physical sequence all the actuators must be configured and communicating (i.e. all shown as CNF). The procedure will exclude from physical wiring list the nodes not responding to the interrogation because powered down or not communicating. This operation can take minutes according to the number of configured nodes connected to the DCM. During the creation of the physical list the nodes are also checked for the correct input-output sequence: if a node is found reversely connected the message ‘Node <name> not properly connected’ appears. The operator must first check the cause of this fault – device reversely connected –, fix it and then run the function again by pressing the Continue softkey. The procedures resumes from where it was stopped. Contrarily, operator may also stop the procedure at this point by pressing [C] key. In this case it is necessary to restore manually the termination of the node that has found reversely connected. The creation of a physical list must be repeated every time any new device is configured in field, or when more nodes are added to the network. Replacing a node, on the contrary, automatically updates the physical list. The physical list is stored as an integral part of configuration file desfile.csv, and as such it can be read and saved. If a configuration file containing the physical list is uploaded, this list is acquired and displayed in screen Cable List. During rebuilding of the physical list, the field nodes are disconnected from the network so as to establish their position. It is thus advisable to run the rebuild procedure while no MODBUS communication is active.



Supervision Memory Allocation List id name type group sts ln. ----------------------------------------[00] L1_01 NETH GRP-01 CNF 001 [01] N100B ICONFDI GRP-02 CNF 001 [02] N105B ICONFDI GRP-02 CNF 001 [03] N107B ICONFDI GRP-02 CNF 001 [04] N300B ICONFDI GRP-03 CNF 001 [05] N506A ICONFDI GRP-04 CNF 001 [06] N507A ICONFDI GRP-04 CNF 001 [07] L1_02 NETT GRP-05 CNF 001 ---------------------------------------- Enter Cable List

Supervision Physical Cabling List id name type group sts ln. ----------------------------------------[00] L1_01 NETH GRP-01 CNF 001 [01] N300A ICONFDI GRP-03 CNF 001 [02] N100B ICONFDI GRP-02 CNF 001 [03] N506A ICONFDI GRP-04 CNF 001 [04] N507A ICONFDI GRP-04 CNF 001 [05] N107B ICONFDI GRP-02 CNF 001 [06] N105B ICONFDI GRP-02 CNF 001 [07] L1_02 NETT GRP-05 CNF 001 ---------------------------------------- Enter StrCheck StopCheck Mem List

Example File desfile.csv . . . . . . . . <devices> L1_01;13;000871010500;GRP-01;Desc_NET_H N100B;9;000933172100;GRP-02;Desc_Nodo1 N105B;9;00a264710300;GRP-02;Desc_Nodo4 N107B;9;000611162000;GRP-02;Desc_Nodo5 N300B;9;000933170700;GRP-03;Desc_Nodo6 N506A;9;000933169900;GRP-04;Desc_Nodo2 N507A;9;00a264719500;GRP-04;Desc_Nodo3 L1_02;14;000871010500;GRP-05;Desc_NET_T . . . . . . . .

Physical Sequence The physical wiring list is automatically transferred to the back-up DCM. Please note the back-up DCM will display the physical sequence from its own point of view, and thus the list in the Slave DCM will be shown in a reverse order as compared to the order shown by the Master DCM.

L1_01

N100B

N506A

N507A

N105B

N107B

N300A

L1_02



FDI Devices ND-01/01 Type NETH Addr Mode 3 Timer Int 250 .4.2.0.8.6.4.2.0 Status 1100000001000000 Warning 0000000000000000 Ena.All Dis.All Ena.Node Dis.Node

8.3.1.2 Enabling the Loop Integrity Check After building the physical wiring list, the system is ready to check the integrity of the communication loops. The NETx nodes use the same hardware as the FDI nodes, but perform a different check strategy due to a new firmware. On the field bus interface card, the DCM coded 293DCM50xxx is equipped with the FDI hardware and the present indications are used to display the status of the NETx nodes.

In the default conditions, the two NETx nodes at both loop ends ensure the correct network termination; on the rear panel of the DCM the following LED indications will be on: The check is started by command StrCheck. For each loop a function is enabled which verifies the physical connection of the two NETx nodes at the ends of each loop, while the DCM is not charged with this activity. The active check is indicated by the flashing of the L3 LED and, in the specific screen of the NETx node, by bits 14 and 15 of Status set at 1. When check is active the system manages the power off of one of the two NETx nodes without generate a false bus interruption event. The system starts functioning regularly after the re-power on of the NETx.

LED 1

LED 2

LED 3

LED 4

SERVICE LED

SERVICE PUSH-BUTTON

Node NETH on the Master DCM

Node NETT on the Slave DCM



Supervision Physical Cabling List id name type group sts ln. ----------------------------------------[00] L1_01 NETH GRP-01 CNF 001 [01] N300B ICONFDI GRP-03 CNF 001 [02] N100B ICONFDI GRP-02 CNF 001 [03] N506A ICONFDI GRP-04 TrA 001 [04] N507A ICONFDI GRP-04 TrB 001 [05] N107B ICONFDI GRP-02 CNF 001 [06] N105B ICONFDI GRP-02 CNF 001 [07] L1_02 NETT GRP-05 CNF 001 ----------------------------------------Cut: N506A|N507A Lid 1 Enter StrCheck StopCheck Mem List

When there is a bus interruption due to the cut-off of a cable, the grounding of the communication line or to a short circuit between the bus conductors, the two NETx nodes acknowledge this situation and, if malfunctioning lasts for the programmed time, the DCM runs the procedure which looks for the fault.

Fault research activates the network terminators of all ICONFDI-type nodes on the closest devices to the fault, and re-establishes communication between the DCM and all the still reachable nodes. In order to do so, both sides of NETx nodes are connected to the network, and LEDs 1 and 2 signal this situation.

Once communication is re-established, a message localizes the fault within the communication loop, and the status of the actuators closest to the fault shows the activation of terminators TrB and TrA. After the fault is isolated, the loop integrity check system is no longer active. The operator must find the fault in the communication cable on the basis of the info provided by the DCM. Once the cable is repaired, the operator must bring the system to its initial status by pressing softkey StopCheck. The integrity check system is re-established by command StrCheck. Warning: It is highly recommended not to issue any configuration command until the networks has

been repaired. After the fault has been isolated the field operator must locate the cable fault and fix it. A configuration command issued in this situation will not restore the cable fault, on the contrary when re-configured the node deactivates its terminators and it may leave the network fault unmanaged. As a result the nodes beyond the network fault that were in good communication status may be turned to NCF or NCO status.

L1_01

N100B

N506A

N507A

N105B

N107B

N300A

L1_02



8.4 Configuration File Managing The DCM can memorize the data of configuration file in different memory types for different usage. The available commands move the configuration file to the appropriate memory location as shown in figure:

The commands from external PC as described in paragraph 7.2: ‘Configuration File Transfer’ refers to the data available in the non-volatile buffer.

Only a Load in File menu of the Groups list screen moves the configuration file data in working memory and causes the DCM to allocate all the memory structure needed for the given configuration.

The configuration file in non-volatile buffer is automatically updated each time the configuration changes by means of a configuration command like Append, Modify or Cancel. The ADMINISTRATOR can also perform a full configuration file re-writing by means of the command Save from the File menu of the Groups list screen. The date and time of the configuration file, displayed in the Master Slave screen, will be updated after re-writing.

The configuration file can be moved in a Flash memory via explicit commands PutFlash and GetFlash as explained in the following paragraph.

Working memory

Flash memory

non-volatile buffer

Load

Save

PutFlash GetFlash

FTP> put desfile.csv

FTP> get desfile.csv Conf. cmd

FTP> put f:/desfile.csv

FTP> get f:/desfile.csv



8.4.1 Transferring the Configuration to the Flash Memory The DCM is equipped with a Flash memory that allows to permanently memorise the configuration file. Once the configuration has been correctly performed, it may be useful to save the file in the DCM Flash memory to be able to retrieve it as needed without the external PC. The procedure for saving the configuration in the Flash memory is as follows: Writing in Flash memory stops all other activities of DCM. To maintain the system fully operational while the PutFlash function is in progress it is advisable to run the function after the control has been transferred to the backup unit.

8.4.2 Retrieving the Configuration from the Flash Memory Follow this procedure to retrieve the configuration file from the Flash memory:


Leave the MODBUS communication lines unconnected, the DCS interface will be not active

during saving

Enter the Groups list screen and select the File menu

Run function PutFlash which copies the configuration file in the Flash memory.


Leave the MODBUS communication lines unconnected, the DCS interface will be not active

during the operation

Enter the Groups list screen and select the File menu

Run function GetFlash which copies the configuration file from the Flash memory to the non-volatile buffer

Load the configuration file by command Load

Run the general configuration function by command Cnf.Nodes from the Groups list. screen



8.5 Resetting the DCM This operation is recommended to clear the DCM internal memory. 1. Turn off the DCM. 2. Turn on the DCM 3. During the boot phase, when DCM shows two lines in the upper area of the display, hit C key of

DCM keyboard 4. ‘RESET RAM’ appears on the screen 5. DCM restarts with all data cleared.

8.6 Software Download on DCM As seen in the previous chapter DCM software update is possible via serial line. In case of a redundant DCM system it is possible to perform the software download without interrupting the plant activities as explained in the following steps:

1. Transfer the control to the Slave unit: this station will continue to communicate to DCS or PLC to maintain the plant control while the other unit is available for software update;

2. Connect PC to the unit to update and execute the relevant procedure as given in paragraph 7.4: ‘Software Update via Serial Line’;

3. When the Master restart it takes the configuration from the Slave; 4. From DCM Slave transfer the control to the Master; 5. Repeat the operations described at point 2 to update the Slave.

8.7 Replacing Batteries Batteries inside CPU shall be replaced when Battery indication on DCM System screen shows they are depleted as described in paragraph 5.7.1:’System’. Battery replacement shall be done when DCM is powered on.

1. Rotate anticlockwise the cover of the battery holder on the CPU module;

2. Push the battery to fully charge the battery holder spring.

3. Quickly release so that the spring pushes out both batteries.

4. Replace the batteries with two 1,5V Alkaline, AA type.

5. Insert the batteries in the battery holder as shown in the figure above.

6. Put back the cover of the battery holder



APPENDIX A: DEFINITION OF THE MODBUS INTERFACE Each channel whose DCM is equipped, has an independent driver to allow the connection of the DCM to the higher level via the MODBUS RTU protocol. This MODBUS protocol is developed according to specification Modbus – IDA: MODBUS Application Protocol Specification V.1.1.b. The DCM MODBUS interface is configured as Slave and implements the following Function Codes :

Code Function QUERY RESPONSE 01 (01 Hex) Read Coil Status 2000 coils 2000 coils

02 (02 Hex) Read Discrete Input 2000 inputs 2000 inputs

03 (03 Hex) Read Holding Register 125 registers 125 registers

04 (04 Hex) Read Input Register 125 registers 125 registers

05 (05 Hex) Write Single Coil 1 coil 1 coil

06 (06 Hex) Write Single Register 1 register 1 register

08 (08 Hex) Loop Back Test n/a n/a

15 (0F Hex) Write Multiple Coils 1968 coils 1968 coils

16 (10 Hex) Write Multiple Registers 120 registers 120 registers

17 (11 Hex) Report Slave ID n/a n/a

The LOOPBACK TEST function implements the following sub-codes:

Sub-Code Function

00 (00 Hex) Return Query Data

01 (00 Hex) Restart Communications Option

10 (0A Hex) Clear Counter and Diagnostic Register

11 (0B Hex) Return Bus Message Count

12(0C Hex) Return Bus Communication Error Count

13 (0D Hex) Return Bus Exception Error Count

14 (0E Hex) Return Slave Message Count

18 (12 Hex) Return Bus Characters Overrun Count

MODBUS data model implemented in DCM is composed of four different data blocks mapped in different data areas indicated as Digital Output (DO), Digital Input (DI), Analogue Output (AO) and Analogue Input (AI). Each Function Code accesses on the appropriate data area and the MODBUS driver locates the data to which the MODBUS command, specified by the Function Code, refers to in the relevant data area.

Function Code Data area

2 - Read Discrete Input Function Code used to read discrete inputs refers to data in DI data area. Discrete inputs are associated to digital signals coming from the field devices.

1 - Read Coil Status 5 - Write Single Coil 15 - Write Multiple Coils

Function Codes used to read or write coils refer to data in DO data area. Coils are associated to the digital commands to the field devices.

4 - Read Input Register

Function Code used to read inputs register refers to data in AI data area. Input registers are associated to analogue or bit-structured data coming from the field devices.

3 - Read Holding Register 6 - Write Single Register 16 - Write Multiple Register

Function Codes used to read or write registers refer to data in AO data area. Registers are associated to analogue commands to the field devices.



A.1 Structure of the MODBUS Interface The DCM MODBUS map is divided in two different memory areas: Field Image that collect data relevant to the field devices connected to DCM; Internal Data that collect data relevant to DCM internal status and communication functioning of

the field devices connected to DCM. ‘Field Image’ area may has different memory models depending on the characteristics of customer’s control system:

MODBUS map ‘Function wise’ where controls and signals of the field devices are collected in banks of homogeneous types (e.g.: all the commands Open_Valve grouped in a bank of DO area; all signals Valve_Fully_Open grouped in a bank of DI area, etc);

MODBUS map ‘Object wise’ where controls and signals are grouped per device (e.g.: all the

commands of the first device followed by all the commands of the second and so on). The selection of the MODBUS map in ‘Function wise’ or ‘Object wise’ influences the allocation of the ‘Internal Data’ and ‘Field Image’ banks at different addresses. The selection of the memory model and the specification of the starting addresses of each bank is given to the DCM by means of the configuration file as described in paragraph 6.1.1: ‘MODBUS map structure definition’. The following schemes represent the generic composition of DCM MODBUS map: ‘Function wise’ model


Bank 0

addr 101 __ addr. 102 __ addr. 103 __ . . .

Bank 1 addr 201 __ addr. 202 __ addr,.203 __ . . .

Bank 2addr 10001 addr 10002 addr 10003 . . .



Field Image

AI area Bank 0

AO area Bank 0

__ __ __

__ __ __

__ __ __

addr. 1 __ addr. 2 __ addr. 3 __ . . .

addr 101 __ addr. 102 __ addr. 103 __ . . .

addr 201 __ addr. 202 __ addr..203 __ . . .

addr 10001 addr 10002 addr 10003 . . .

__ __ __

__ __ __

__ __ __


addr 1 __ addr. 2 __ addr. 3 __ . . .

addr 1 __ addr. 2 __ addr. 3 __ . . .

Internal data zone



‘Object wise’ model The following paragraphs give a detailed description of each group of signals.

A.1.1 DI area – Internal Data zone The Internal Data zone in MODBUS DI area is composed of a section for current DCM internal status and a section that reports the communication status of the devices connected to the DCM. When the digital inputs is set to 1 it means that the relevant node in not communicating. This second section may be defined in the following three different modes: Internal Data zone in ‘Legacy mode’ In ‘Legacy mode’ the Internal Data reserves one digital input to each node as they are declared in the section devices to indicate the current communication status of that device. ‘Legacy mode’ is the structure of the MODBUS map available on the DCM equipped with software revision 3.02.00.xx or older. Internal Data zone in ‘Packed mode’ In ‘Packed mode’ the Internal Data reserves two digital inputs for each Router as they are declared in the section topology corresponding to the ‘Near side’ and to the ‘Far side’ of the Router and then one digital input to each node as they are declared in the section devices. Internal Data zone in ‘Extended mode’ ‘Extended mode’ is similar to ‘Packet mode’ but in this case the communication status of Router, node type NET_X and node type ICON are allocated in separate blocks of contiguous digital inputs. In this way a future expansion of the loop will not affect the previous MODBUS map structure, but will cause the adding in the relevant section of the new communication indication. The composition of the Internal Data does not vary depending on the MODBUS structure selected, but it is only ‘allocated’ to the starting address selected for the Internal Data area. The following table shows the composition of the Internal Data giving the relative numbering of the digital inputs. The address that the MODBUS Master will use to access to the data is given by adding the starting address of the Internal Data zone as it has been set in the DCM configuration file.


Field Image


Internal data zoneExternded Packed Legacy

DO area

AI area

AO area

__ __ __

__ __ __

__ __ __

addr 1000 __ addr. 1001 __ addr. 1002 __ . . .


__ __ __

__ __ __

__ __ __


addr 3000 __ addr. 3001 __ addr. 3002 __ . . .

addr 3000 __ addr. 3001 __ addr. 3002 __ . . .



MODBUS DI area – Internal Data zone in Legacy Mode

Input # Description Set to 0 Set to 1

1 Physical digital input #1 Input inactive Input active




5-8 Reserved

9 DCM unit connected Master Slave

10 DCM status The unit does not have control The unit has control

11 Exchange in progress The unit is taking control

12 Bus interruption detected and fixed No bus interruption Bus interruption detected and fixed

13 Back-up unit ready Back-up unit not available Back-up unit in stand-by

14-19 Reserved

20 Network configuration The network is correctly configured

The network is not configured yet

21 Reserved

22 One field device not communicating No communication errors Almost one field device is not communicating

23 All field devices not communicating No communication errors All field devices are not communication

24 Data base status Configuration loaded Configuration database empty

25-32 Reserved

33 Field bus status Intact field bus At least one field device is not communicating

34 Status of internal DCM communication interface to the field Node communicating Node not communicating

35 Communication status first node declared in the device section of configuration file Node communicating Node not communicating

36 Communication status second node declared in the device section of configuration file Node communicating Node not communicating

37 Communication status third node declared in the device section of configuration file Node communicating Node not communicating

cont. . . .

cont. . . .

cont. . . .

cont. . . .

cont. . . .



MODBUS DI area – Internal Data zone in Packed Mode






5-8 Reserved






14-19 Reserved



21 Reserved




25-32 Reserved



35 Communication status of near side of the first Router declared in the router section of configuration file

Node communicating Node not communicating



cont. . . .

cont. Communication status of near side of the last Router declared in the router section of configuration file




cont. Communication status first node declared in the device section of configuration file Node communicating Node not communicating

cont. Communication status second node declared in the device section of configuration file Node communicating Node not communicating

cont. Communication status third node declared in the device section of configuration file

cont. . . .

cont. . . .

cont. . . .

cont. . . .



MODBUS DI area – Internal Data zone in Extended Mode






5-8 Reserved






14-19 Reserved



21 Reserved




25-32 Reserved







cont. . . .





In ‘Extended mode’ these digital inputs are available for future loop expansion

115 Communication status first NET_H declared in the device section of configuration file Node communicating Node not communicating

116 Communication status first NET_T declared in the device section of configuration file Node communicating Node not communicating

cont. . . .

cont. Communication status last NET_H declared in the device section of configuration file Node communicating Node not communicating

cont. Communication status last NET_T declared in the device section of configuration file Node communicating Node not communicating

In ‘Extended mode’ these digital inputs are available for future loop expansion

151 Communication status first ICON declared in the device section of configuration file Node communicating Node not communicating

152 Communication status second ICON declared in the device section of configuration file Node communicating Node not communicating

cont. . . .



A.1.2 DI area – Field Image Each Biffi actuators series ICON or ICON2000 with LONWORKS interface card can transmit to the DCM a set of information related to the current status of the actuator. The communication elements that are represented by digital inputs are stored in the Field Image of the DI area of DCM MODBUS map. In order to minimise the MODBUS map it is possible to select the signals that have to be exchanged between the Host and the DCM by means of the configuration file. The organization of these information in the DI area depends on what type of structure - ‘Function wise’ or ‘Object wise’ - has been selected for the MODBUS map by means of configuration file.

A.1.2.1 DI in ‘Object wise’ structure In ‘Object wise’ structure all the information related to the first actuator are grouped in a contiguous block of digital inputs. Default starting address is 1000. Than the map continues with the same sequence of information related to the next actuators without leaving any interruption among digital inputs. In the following table is shown the sequence for the first two ICON2000 actuators where all the digital inputs available have been selected.

DI Description Set to 0 Set to 1

1000 MOV_01 Fully Open Valve not open Valve in Fully Open position

1001 MOV_01 Fully Close Valve not closed Valve in Fully Closed position

1002 MOV_01 Opening movement No movement in progress Valve moving in Open direction

1003 MOV_01 Closing movement No movement in progress Valve moving in Closing direction

1004 MOV_01 Monitor relay Valve not available Valve available for remote control

1005 MOV_01 Alarm No alarm present At least one alarm present

1006 MOV_02 Fully Open Valve not open Valve in Fully Open position

1007 MOV_02 Fully Close Valve not closed Valve in Fully Closed position

1008 MOV_02 Opening movement No movement in progress Valve moving in Open direction

1009 MOV_02 Closing movement No movement in progress Valve moving in Closing direction

1010 MOV_02 Monitor relay Valve not available Valve available for remote control

1011 MOV_02 Alarm No alarm present At least one alarm present

. . . . . . . . . . . .

A.1.2.2 DI in ‘Function wise’ structure In ‘Function wise’ structure the information coming from field devices are available in the related bank as defined in the DCM configuration file, where it is set the starting address of each bank and the element associated. In the following table it is represented the sequence of the signals from the first two actuators where all the digital inputs available have been selected and split in 6 different banks starting respectively at address 1, 101, 201, 301, 401 and 501.

DI Area Bank 1 2 3 4 5 6

Signal Actuator

Fully Open Fully Close Opening Closing Monitor relay Alarm

MOV_01 1 101 201 301 401 501

MOV_02 2 102 202 302 402 502

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .



A.1.3 DO area – Internal Data zone The Internal Zone in MODBUS DO area is composed of a set of coils correspondents to the four physical digital output available on the DCM. The coils that are not managed by ‘equation’ written in the info section of configuration file, are available to the user as generic output signal driven by MODBUS protocol. When the coil is set to 1 the relevant digital output is activated and the associate relay closes the output contact. MODBUS DO area – Internal Data zone

Mode selected Legacy Packet Exten. Description Set to 0 Set to 1

1 Physical digital output #1 Relay not energised Relay energised




A.1.4 DO area – Field Image Each Biffi actuators series ICON or ICON2000 with LONWORKS interface card can receive from DCM a set of commands to control the actuator. The communication elements that are represented by digital output are stored in the Field Image of the DO area of DCM MODBUS map. In order to minimise the MODBUS map it is possible to select the commands that Host will send to the DCM by means of the configuration file. The organization of these information in the DO area depends on what type of structure - ‘Function wise’ or ‘Object wise’ - has been selected for the MODBUS map by means of configuration file.

A.1.4.1 DO in ‘Object wise’ structure In ‘Object wise’ structure all the commands related to the first actuator are grouped in a contiguous block of coils. Default starting address is 1000. Than the map continues with the same sequence of information related to the next actuators without leaving any interruption among coils. In the following table is shown the sequence for the first two actuators where all the commands available for an ICON or ICON2000 actuator have been selected.

DO Description Set to 0 Set to 1

1000 MOV_01 Open command No command active Open command active

1001 MOV_01 Close command No command active Close command active

1002 MOV_01 Stop command No command active Stop command active

1003 MOV_01 Open Interlock No command active Open Interlock active

1004 MOV_01 Close Interlock No command active Close Interlock active

1005 MOV_01 ESD command No command active t ESD command active

1006 MOV_01 Enable Setpoint ON/OFF functioning enabled Positioner functioning enabled

1007 MOV_02 Open command No command active Open command active

1008 MOV_02 Close command No command active Close command active

1009 MOV_02 Stop command No command active Stop command active

1010 MOV_02 Open Interlock No command active Open Interlock active

1011 MOV_02 Close Interlock No command active Close Interlock active

1012 MOV_02 ESD command No command active t ESD command active

1013 MOV_02 Enable Setpoint ON/OFF functioning enabled Positioner functioning enabled

. . . . . . . . . . . .



A.1.4.2 DO in ‘Function wise’ structure In ‘Function wise’ structure the same commands are available in the related bank as defined in the DCM configuration file, where it is set the starting address of each bank and the command associated. In the following table is represented the sequence of the commands to the first two actuators where all the digital outputs available have been selected and split in 7 different banks starting respectively at address 1, 101, 201, 301, 401, 501 and 601.

DO Area Bank 1 2 3 4 5 6 7

Signal Actuator

Open command

Close command

Stop command

Open Interlock

Close Interlock

ESD command

Enable Setpoint

MOV_01 1 101 201 301 401 501 601 MOV_02 2 102 202 302 402 502 602

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .



A.1.5 AI area – Field Image The communication elements received from Biffi actuators series ICON or ICON2000 with LONWORKS interface card that are represented by registers are stored in the Field Image of the AI area of DCM MODBUS map. In order to minimise the MODBUS map it is possible to select the signals that have to be exchanged between the Host and the DCM by means of the configuration file. The organization of these information in the AI area depends on what type of structure - ‘Function wise’ or ‘Object wise’ - has been selected for the MODBUS map by means of configuration file.

A.1.5.1 AI in ‘Object wise’ structure In ‘Object wise’ structure all the information related to the first actuator are grouped in a contiguous block of input registers starting, by default, from Register number 3000. Than the map continues with the same sequence of information related to the next actuators without leaving any interruption among registers. In the following table is shown the sequence for the first two actuators where all the input registers available for an ICON or ICON2000 actuator have been selected.

AI Description Note

3000 MOV_01 Current position See Note 1

3001 MOV_01 Current torque See Note 1

3002 MOV_01 Actuator status See Note 2

3003 MOV_01 Warning See Note 3

3004 MOV_01 Alarm See Note 4

3005 MOV_02 Current position See Note 1

3006 MOV_02 Current torque See Note 1

3007 MOV_02 Actuator status See Note 2

3008 MOV_02 Warning See Note 3

3009 MOV_02 Alarm See Note 4

. . . . . . . . .

A.1.5.2 AI in ‘Function wise’ structure In ‘Function wise’ structure the same information are available in the related bank as defined in the DCM configuration file, where it is set the starting address of each bank and the element associated. In the following table is represented the sequence of the input registers of the first two actuators where all the analogue inputs available have been selected and split in 5 different banks starting respectively at address 1, 101, 201, 301 and 401.

AI Area Bank 1 2 3 4 5

Element Actuator

Current position (see Note1)

Current torque (see Note1)

Actuator status (see Note2)

Warning (see Note3)

Alarm (see Note4)

MOV_01 1 101 201 301 401 MOV_02 2 102 202 302 402

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .



Note 1: the coding of analogue quantities for each MODBUS line depends on the conversion factor declared in section

nodetype of the configuration file. If the field is set as 0: the resolution of analogue values is as set for the LonWorks protocol. The real position and torque values are obtained by dividing by 200 the value shown by the corresponding register. For example: register value = 0 (0x0000) real value = 0.00%

register value = 5000 (0x1388) real value = 25.00% register value = 15000 (0x3A98) real value = 75.00% register value = 20000 (0x4E20) real value = 100.00%

If the field is set as 12: the resolution of analogue values is scaled by the DCM on 12 bits. For example: register value = 0 (0x000) real value = 0.00%

register value = 1023 ( 0x3FF) real value = 25.00% register value = 3071 (0xBFF) real value = 75.00% register value = 4095 (0xFFF) real value = 100.00%

Note 2: ‘Actuator status’ has to be considered as 16-bit structures, where bit 0 is the least significant bit.

bit 15= Selector in “Off” position bit 14= Selector in “Local” position bit 13= Selector in “Remote” position bit 12= Local configuration in progress bit 11= ESD command active bit 8-10= Reserved bit 7= Bus input connected to the network (term. A) bit 6= Bus input connected to the network (term. B) bit 0-5= Reserved

Note 3: ‘Warning’ has to be considered as 16-bit structures, where bit 0 is the least significant bit.

bit 15-13= Reserved bit 12= Actuator in Local configuration bit 11= ESD active bit 10-5= Reserved bit 4= Control card overheated bit 3= High torque in opening bit 2= High torque in closing bit 1= Reserved bit 0= Stopped by local STOP push-button

Note 4: ‘Alarm’ has to be considered as 16-bit structures, where bit 0 is the least significant bit.

bit 15-13= Reserved bit 12= Power loss bit 11= Position sensor error bit 10= Reserved bit 9= Motor stalled bit 8= Motor overheating bit 7= K2 contactor error bit 6= K1 contactor error bit 5= Phase loss bit 4= Reserved bit 3= Max torque in opening bit 2= Max torque in closing bit 1= Reserved bit 0= Push-button error



A.1.6 AO area – Field Image Each Biffi actuators series ICON or ICON2000 with LONWORKS interface card can receive from DCM a position set point command. The communication elements that are represented by analogue output register are stored in the Field Image of the AO area of DCM MODBUS map. In order to minimise the MODBUS map, if the actuator is not controlled by position set point, is it possible do not select this command in the DCM configuration file. The organization of these information in the AO area depends on what type of structure - ‘Function wise’ or ‘Object wise’ - has been selected for the MODBUS map by means of configuration file.

A.1.6.1 AO in ‘Object wise’ structure In ‘Object wise’ structure all the information related to the first actuator are grouped in a contiguous block of output registers starting, by default, from Register number 3000. Than the map continues with the same sequence of information related to the next actuators without leaving any interruption among registers. In the following table is shown the sequence for the first two actuators:

AO Description Note

3000 MOV_01 Position set point See Note 5

3001 MOV_02 Position set point See Note 5

. . . . . . . . .

A.1.6.2 AO in ‘Function wise’ structure In ‘Function wise’ structure the same information are available in the related bank as defined in the DCM configuration file, where it is set the starting address of each bank and the element associated. In the following table is represented the sequence of the output registers of the first two actuators where all the analogue output available have been selected and split in 1 banks starting at address 1.

AO Area Bank 1

Element Actuator

Current Set point (see Note5)

MOV_01 1 MOV_02 2

. . . . . .

. . . . . .

Note 5: the coding of analog quantities for each MODBUS line depends on the conversion factor declared in section

nodetype of the configuration file. If the field is set as 0: the resolution of analog values is as set for the LonWorks protocol. It is necessary to write the value of the required position multiplied by 200 in the corresponding register. For example: set-point = 0.00% value to be written in the register = 0 (0x0000)

set-point = 25.00% value to be written in the register = 5000 (0x1388) set-point = 75.00% value to be written in the register = 15000 (0x3A98) set-point = 100.00% value to be written in the register = 20000 (0x4E20)

If the field is set as 12: the resolution of analog values is scaled by the DCM on 12 bits. For example: set-point = 0.00% value to be written in the register = 0 (0x000)

set-point = 25.00% value to be written in the register = 1023 (0x3FF) set-point = 75.00% value to be written in the register = 3071 (0xBFF) set-point = 100.00% value to be written in the register = 4095 (0xFFF)



A.2 MODBUS Protocol Details After having described the composition of the MODBUS map, in this chapter are given detail on how to access to the different area data. Starting address and number of elements to read or write depend on the MODBUS map composition and memory model selected.

Function Code 01 (01 Hex) Read Coil Status This function code is used to read from 1 to 2000 contiguous On/Off status of discrete outputs (coils) in the DO area of DCM interface. In the request message the MODBUS Master specifies the address of the first coil and the number of coils. Since in the MODBUS protocol coils are addressed starting from 0, the coils numbered 1-16 are addressed 0-15. The coils in the response message are packet as one coil per bit of the data field. This function code is useful to read back the status of the last commands issued by Host system. Example: request to read the status the first 20 discrete outputs

Request Response Field name (Hex) Field name (Hex) (Binary) Function 01 Function 01 Starting Address Hi 00 Byte Count 03 Starting Address Lo 00 Output status 7-0 CD 1100 1101 Quantity of outputs Hi 00 Output status 15-8 63 0110 0011 Quantity of outputs Lo 14 Output status 20-16 05 0000 0101

Function Code 02 (02 Hex) Read Discrete Input This function code is used to read from 1 to 2000 contiguous status of discrete inputs in the DI area of DCM interface. In the request message the MODBUS Master specifies the address of the first input and the number of inputs. Since in the MODBUS protocol inputs are addressed starting from 0, the input numbered 1-16 are addressed 0-15. The inputs in the response message are packet as one input per bit of the data field. This function code is useful to read the current status of DCM or the field devices. Example: request to read the inputs 1000-1021 (22 inputs)

Request Response Field name (Hex) Field name (Hex) (Binary) Function 02 Function 02 Starting Address Hi 03 Byte Count 03 Starting Address Lo E7 Output status 1007-1000 EB 1110 1011 Quantity of outputs Hi 00 Output status 1015-1008 E9 1110 1001 Quantity of outputs Lo 16 Output status 1022-1016 35 0011 0101

Function Code 03 (03 Hex) Read Holding Register

This function code is used to read from 1 to 125 contiguous holding registers in the AO area of DCM interface. In the request message the MODBUS Master specifies the starting address and the number of registers. Since in the MODBUS protocol registers are addressed starting from 0, the registers numbered 1-16 are addressed 0-15. The register data in the response message are packet as two bytes per register of the data field. This function code is used to read back the status of the last commands issued through registers by Host system.



Example: request to read the registers 1000-1001 (2 registers)

Request Response Field name (Hex) Field name (Hex) (Binary) Function 03 Function 03 Starting Address Hi 03 Byte Count 04 Starting Address Lo E7 Register value Hi (1000) 20 Quantity of outputs Hi 00 Register value Lo(1000) E6 Quantity of outputs Lo 02 Register value Hi (1001) 13 Register value Lo(1001) 88

Function Code 04 (04 Hex) Read Input Register This function code is used to read from 1 to 125 contiguous input registers in the AI area of DCM interface. In the request message the MODBUS Master specifies the starting address and the number of registers. Since in the MODBUS protocol registers are addressed starting from 0, the registers numbered 1-16 are addressed 0-15. The register data in the response message are packet as two bytes per register of the data field. By means of this function code Host system can read the current status of the analogue and bit-structure data of the actuators connected to DCM. Example: request to read the registers 1000-1002 (3 registers)

Request Response Field name (Hex) Field name (Hex) (Binary) Function 04 Function 04 Starting Address Hi 03 Byte Count 06 Starting Address Lo E7 Register value Hi (1000) 20 Quantity of outputs Hi 00 Register value Lo(1000) E6 Quantity of outputs Lo 03 Register value Hi (1001) 00 Register value Lo(1001) 4E Register value Hi (1002) 8C Register value Lo(1002) 26

Function Code 05 (05 Hex) Write Single Coil This function code is used to write a single output to either ON or OFF in the DO area of DCM interface. The requested ON/OFF state is specified by a constant in the request data field. A value of FF00 Hex request the output to be ON. A value of 0000 Hex request the output to be OFF. In the request message the MODBUS Master specifies the address of the coil to be forced. Since in the MODBUS protocol coils are addressed starting from 0, the coil numbered 1 is addressed as 0. The normal response is an echo of the request. This function code is used to send a single On/Off command to a selected actuator. Example: request to write coil 1000 to ON

Request Response Field name (Hex) Field name (Hex) (Binary) Function 05 Function 05 Output Address Hi 03 Output Address Hi 03 Output Address Lo E7 Output Address Lo E7 Output value Hi FF Output value Hi FF Output value Lo 00 Output value Lo 00



Function Code 06 (06 Hex) Write Single Register This function code is used to write a single holding register in the AO area of DCM interface. In the request message the MODBUS Master specifies the address of the register to be written. Since in the MODBUS protocol registers are addressed starting from 0, the registers numbered 1 is addressed as 0. The normal response is an echo of the request. This function code is used to send a single set point command to a selected actuator. Example: request to write holding register 3000 to value 4095 (Hex 0FFF)

Request Response Field name (Hex) Field name (Hex) (Binary) Function 06 Function 06 Register Address Hi 0B Register Address Hi 0B Register Address Lo B7 Register Address Lo B7 Register value Hi 0F Register value Hi 0F Register value Lo FF Register value Lo FF

Function Code 08 (08 Hex) Loop Back Test MODBUS function code 8 provides a series of tests for checking the communication system between the Master MODBUS an the DCS. The function uses a two-byte sub-function code field in the query to define the type of test to be performed.

Request Response Field name (Hex) Field name (Hex) (Binary) Function 08 Function 08 Sub-function Hi 00 Sub-function Hi 00 Sub-function Lo 00 Sub-function Lo 00 Data (any) 0F Data (any) 0F

The following sub-function codes are implemented.

Sub-function 00 (00 Hex) Return Query Data The data passed in the request data field is to be returned (looped back) in the response.

Sub-function Data field (Request) Data field (Response) 00 00 Any Echo request data

Sub-function 01 (00 Hex) Restart Communications Option The DCM serial line port that receives the request with data field set to 0000 Hex is initialized and restarted. If the data field is set to FF00 Hex it also clear its communication event counter.

Sub-function Data field (Request) Data field (Response) 00 01 00 00 Echo request data 00 01 FF 00 Echo request data

Sub-function 10 (0A Hex) Clear Counter and Diagnostic Register All counters in diagnostic registers are cleared. Counters are also cleared upon power-up.

Sub-function Data field (Request) Data field (Response) 00 0A 00 00 Echo request data



Sub-function 11 (0B Hex) Return Bus Message Count The response data field returns the quantity of messages that DCM has detected on the communication system since its last restart, clear counter operation or power-up.

Sub-function Data field (Request) Data field (Response) 00 0B 00 00 Total message count

Sub-function 12(0C Hex) Return Bus Communication Error Count The response data field returns the quantity of CRC errors that DCM has detected on the communication system since its last restart, clear counter operation or power-up.

Sub-function Data field (Request) Data field (Response) 00 0C 00 00 CRC error count

Sub-function 13 (0D Hex) Return Bus Exception Error Count The response data field returns the quantity of MODBUS exception responses that DCM has returned since its last restart, clear counter operation or power-up.

Sub-function Data field (Request) Data field (Response) 00 0D 00 00 Exception error count

Sub-function 14 (0E Hex) Return Slave Message Count The response data field returns the quantity of messages addressed to the DCM that the unit has processed since its last restart, clear counter operation or power-up.

Sub-function Data field (Request) Data field (Response) 00 0E 00 00 Salve message count

Sub-function 18 (12 Hex) Return Bus Characters Overrun Count The response data field returns the quantity of messages addressed to the DCM that the unit could not handle due to a character overrun condition its last restart, clear counter operation or power-up. A character overrun is caused by data character arriving at the port faster than they can be stored or by the loss of character due to hardware malfunction.

Sub-function Data field (Request) Data field (Response) 00 12 00 00 Salve character overrun count

Function Code 15 (0F Hex) Write Multiple Coils This function code is used to force each coil in a sequence of coils (from 1 to1968 coils) to either ON or OFF in the DO area of DCM interface. In the request message the MODBUS Master specifies the address of the first coil to be forced and the numbers of coils and their values. Since in the MODBUS protocol coils are addressed starting from 0, the coil numbered 1 is addressed as 0. The normal response returns the function code, starting address and quantity of coils forced. This function code is useful to send in one shot a set of On/Off commands to more actuators.



Example: request to write a series of 10 coils staring from 1000

Request Response Field name (Hex) Field name (Hex) (Binary) Function 0F Function 0F Starting Address Hi 03 Starting Address Hi 03 Starting Address Lo E7 Starting Address Lo E7 Quantity of Output Hi 00 Quantity of Output Hi 00 Quantity of Output Lo 0A Quantity of Output Lo 0A Byte count 02 Output value Hi (1007-1000) A5 Output value Lo (1009 -1008) 01

Function Code 16 (10 Hex) Write Multiple Registers This function code is used to write a block of contiguous registers (from 1 to120 registers) in the AO area of DCM interface. In the request message the MODBUS Master specifies the address of the first register to be written the number of registers to write and the requested written values. Since in the MODBUS protocol registers are addressed starting from 0, the register numbered 1 is addressed as 0. The normal response returns the function code, starting address and quantity of register written. This function code is used to send the set point values to more actuators. Example: request to write register 3000 at 4095 (Hex 0FFF) and register 3001 at 1023 (Hex 03FF)

Request Response Field name (Hex) Field name (Hex) (Binary) Function 10 Function 10 Starting Address Hi 0B Starting Address Hi 0B Starting Address Lo B7 Starting Address Lo B7 Quantity of Register Hi 00 Quantity of Register Hi 00 Quantity of Register Lo 02 Quantity of Register Lo 02 Byte count 04 Register value Hi 0F Register value Lo FF Register value Hi 03 Register value Lo FF

Function Code 17 (11 Hex) Report Slave ID This function code is used to read the description of the type, the current status and other information specific of the DCM. The format of the response is shown in the following example:

Request Response Field name (Hex) Field name (Hex) Description Function 11 Function 11 Byte count 18 Slave ID 00 Run indicator FF DCM specific: data 11 ASCII chr “BIFFI DCMr3” DCM specific: Sw rev 11 ASCII chr “03.02.01.38”



MODBUS Exception Responses When a DCS or PLC master sends a MODBUS request to DCM it is expected a normal response. One of four possible events can occur from master’s query:

If DCM receives the request without a communication error and can handle the query normally, it returns a normal response.

If DCM does not receive the request due to a communication error, no response is returned. Master will eventually process a timeout condition for the request.

If DCM receives the request, but detects a communication error (parity or CRC), no response is returned. Master will eventually process a timeout condition for the request.

If DCM receives the request without a communication error, but cannot handle it (for example, if the DCM is running a node configuration function), the DCM will return an exception response informing the master of the nature of the error.

The exception response message has two field that differentiate it from a normal response: Function Code Field: in normal response the DCM echoes the function code of the original request in

the function code field of the response. In an exception response DCM sets the MSB of the function code to 1.

Data Field: the exception error code is returned: this define the condition that caused the exception. DCM manages the following exception codes:

Example: request to read the inputs 1000-1021 (22 inputs) and exception response

Request Response Field name (Hex) Field name (Hex) (Binary) Function 02 Function 82 Starting Address Hi 03 Exception Code 06 Starting Address Lo E7 Quantity of outputs Hi 00 Quantity of outputs Lo 16

Exception Code Meaning

01 - ILLEGAL FUNCTION The function code received in the query is not an allowable action.

02 – ILLEGAL DATA ADDRESS The data address received in the query is not valid or it is related to a non defined area.

06 – SLAVE DEVICE BUSY DCM cannot respond to master’ s query because is engaged in a long-duration program command like node configuration.



APPENDIX B: CABLE SELECTION This Appendix is based on the following documents:

LONWORKS® FTT-10 Free Topology Transceiver User’s Guide - Version 6 - Echelon® Corporation

LONMARK™ Layers 1-6 Interoperability Guidelines - Version 3.0 - LONMARK™ Interoperability Association

LONWORKS® Engineering Bulletin - Junction Box and Wiring Guideline for Twisted Pair LONWORKS® Networks - November 2001

These documents are available on the Echelon website: www.echelon.com; refer to them for any further information. Field device as ICON2000 actuators implement LONWORKS protocol using the FTT-10A Free Topology Transceiver that is the component that drives the communication function. The characteristics of this transceiver are stated in the Echelon literature and can be summarised as follow: • the channel works in bus topology with a double-terminated network; • fieldbus media is an unshielded twisted pair cable; • communication speed is set at 78Kbps; • up to 60 actuators can be used on each loop; • if the bus length exceeds the maximum length indicated above, or if the total number of nodes is

more than 60 for each loop, it is necessary to install a repeater to increase the limit of the single loop. The cable used for the fieldbus network is a crucial item and a wrong choice or a wrong execution may compromise the total system behaviour. The cable used can affect system performance: the larger the system, the more important the choice of the cable. System response depends on a range of factors, for example conductor resistance, conductors’ mutual capacity, propagation speed, etc. In the light of the above, the cable suitable for our applications and listed in Echelon literature is:

Cable Type Max bus length [metres]

16AWG/1.3mm2 – Twisted pair cable 1400

This is the cable that is assumed to be used for the discussions in this document. In general, the following requirements must be met: • Communication channel cable must be separate from the high voltage cable • Cable average temperature must not exceed +55°C, even though the individual segments of the cable

can reach +85°C;



B.1 Specification for 16AWG/1.3 mm – Twisted pair cable Stranded pair (19x29), tinned copper.

Min Type Max Unit Condition

DC resistance, each conductor 14.0 14.7 15.5 ohm/km 20°C for ASTM D 4566

DC resistance, unbalanced 5% 20°C for ASTM D 4566

Mutual capacitance 55.9 nF/km for ASTM D 4566

Characteristic impedance 92 100 108 ohm 64kHz to 1MHz for ASTM D 4566

Attenuation 20kHz 64KHz 78KHz

156KHz 256KHz 512KHz 772KHz

1000KHz

1.3 1.9 2.2 3.0 4.8 8.1

11.3 13.7

dB/km

20°C for ASTM D 4566

Propagation delay 5.6 ns/m 78KHz

The Echelon literature indicates the following Belden cables as compliant to the 16AWG/1,3mm2, dia 1,29mm - twisted pair cable specification: BELDEN 8471 Tinned copper, PVC insulated, twisted pair, Chrome PVC jacket

BELDEN 85102 Tinned copper, Tefzel insulated. Clear Tefzel jacket. 300V RMS 150°C

Other selected producers are indicated in Echelon document:

LONWORKS® Engineering Bulletin - Junction Box and Wiring Guideline for Twisted Pair LONWORKS® Networks - November 2001



APPENDIX C: ICON2000 COMMUNICATION INTERFACE An ICON2000 actuator equipped with LONWORKS interface card is able communicate a wide set of data for a complete control and managing. This chapter lists all the communication objects implemented in ICON2000 with a brief explanation.

C.1 Actuator runtime input variables These communication objects are the commands to the actuator and are normally received from the MODBUS interface. Each data can be selected in the DCM configuration file to link the single element to a coil in the MODBUS interface. These data are also available at DCM specific screen. nv # nv name nv type Units Min Max Comments

0 nviDriveOpen SNVT_lev_disc - ST_OFF ST_ONOPEN command will be initiated on a transition from ST_OFF to ST_ON

1 nviDriveClose SNVT_lev_disc - ST_OFF ST_ONCLOSE command will be initiated on a transition from ST_OFF to ST_ON

2 nviStop SNVT_lev_disc - ST_OFF ST_ONSTOP command will be initiated on a transition from ST_OFF to ST_ON

5 nviESD SNVT_lev_disc - ST_OFF ST_ONST_ON = Emergency Shut Down ST_OFF = Normal operation

6 nviSetpoint SNVT_lev_percent % 0.0 100.0 Setpoint input (active in inching mode only)

C.2 Actuator output variables These communication objects are the current state of the actuator and are normally forwarded to the MODBUS interface. Each data can be selected in the DCM configuration file to link the single element to a coil in the MODBUS interface. These data are also available at a DCM specific screen. nv # nv name nv type Units Min Max Comments

7 nvoValveOpen SNVT_lev_disc - ST_OFF ST_ON ST_ON when valve fully open, else ST_OFF

8 nvoValveClosed SNVT_lev_disc - ST_OFF ST_ON ST_ON when valve fully closed, else ST_OFF

9 nvoOpening SNVT_lev_disc - ST_OFF ST_ON ST_ON when valve opening, else ST_OFF

10 nvoClosing SNVT_lev_disc - ST_OFF ST_ON ST_ON when valve closing, else ST_OFF

11 nvoMonitorRelay SNVT_lev_disc - ST_OFF ST_ON ST_ON when monitor relay closed, else ST_OFF

12 nvoAlarmActive SNVT_lev_disc ST_OFF ST_ONST_ON if any of the alarm conditions is present, else ST_OFF

13 nvoPosition SNVT_lev_percent % 0.0 100.0 Current valve position, in % of full position

14 nvoTorque SNVT_lev_percent % -150.0 150.0 Current valve torque, in %.

15 nvoActuatorState SNVT_state - - - See table 1 below

16 nvoWarning SNVT_state - - - Warnings. See table 2 below

17 nvoAlarm SNVT_state - - - Alarms. See table 3 below



Table 1 – Actuator State Bit Number Value Bit 0 reserved

Bit 1 reserved

Bit 2 reserved

Bit 3 reserved

Bit 4 reserved

Bit 5 reserved

Bit 6 Relay B connected to the Network

Bit 7 Relay A connected to the Network

Bit 8 reserved

Bit 9 reserved

Bit 10 reserved

Bit 11 ESD Command in progress

Bit 12 ICON on Local Configuration mode

Bit 13 Local selector on REMOTE

Bit 14 Local selector on LOCAL

Bit 15 Local selector on OFF

Table 2 – Actuator Warning Bit Number Value Bit 0 STOP depressed during remote

Bit 1 reserved

Bit 2 High torque in closing

Bit 3 High torque in opening

Bit 4 High electronic card temperature

Bit 5 reserved

Bit 6 reserved

Bit 7 reserved

Bit 8 reserved

Bit 9 reserved

Bit 10 reserved

Bit 11 reserved

Bit 12 reserved

Bit 13 reserved

Bit 14 reserved

Bit 15 reserved

Table 3 – Actuator Alarm Bit Number Value Bit 0 Incorrect pushbutton coding

Bit 1 reserved

Bit 2 Max. Torque in closing

Bit 3 Max. Torque in opening

Bit 4 reserved

Bit 5 Phase loss

Bit 6 K1 contactor failure

Bit 7 K2 contactor failure

Bit 8 Motor overheating

Bit 9 Motor stalled

Bit 10 reserved

Bit 11 Position sensor failure

Bit 12 Power failure

Bit 13 reserved

Bit 14 reserved

Bit 15 reserved



C.3 Actuator setup and configuration variables These data are related to the actuator behaviour, are exchanged only with the DCM and are available at a DCM specific screen; they are not propagated to the MODBUS interface. nv # nv name nv type Units Min Max Default

value Comments

18 nviHeartbeat SNVT_time_sec s 0.0 999.0 1.0 Heartbeat value for all output nv’s 0.0 = Heartbeat disabled

19 nviPosSensitivty SNVT_lev_percent % 0.0 100.0 1.0 Position sensitivity, in %

20 nviTrqSensitivty SNVT_lev_percent % 0.0 100.0 5.0 Torque sensitivity, in %

21 nviESDAction SNVT_hvac_overid - HVO_OFF HVO_NUL HVO_OFFAction to take when an ESD condition occurs. See table 4 below

22 nviESDTrqAlrmOvr SNVT_lev_disc - ST_OFF ST_ON ST_OFF ST_ON = ESD torque alarm override ST_OFF = No override

23 nviCloseOnPos SNVT_lev_disc - ST_OFF ST_ON ST_ON ST_ON = Close on Position ST_OFF = Close on Torque

24 nviOpenOnPos SNVT_lev_disc - ST_OFF ST_ON ST_ON ST_ON = Open on Position ST_OFF = Open on Torque

25 nviTorqueBand SNVT_lev_percent % 0.0 8.0 4.0 Torque band, defines the vicinity of the extreme position where a torque end of travel can occur

26 nviCWToClose SNVT_lev_disc - ST_OFF ST_ON ST_ON ST_ON = Clockwise to Close ST_OFF = Anticlockwise to Close

31 nviInchingMode SNVT_lev_disc - ST_OFF ST_ON ST_OFF ST_ON = Inching remote control mode ST_OFF = On/Off remote control mode

32 nviDeadband SNVT_lev_percent % 0.1 10.0 10.0 Deadband, used in inching mode

33 nviFeedbackDelay SNVT_time_f s 1.0 60.0 1.0 Feedback Delay (delay between interventions time, used in inching mode only)

34 nviReversalTime SNVT_time_f s 1.0 10.0 0.5 Reversal Time

35 nviJammedValveTO SNVT_time_f s 2.0 100.0 2.0 Jammed Valve Timeout

36 nviTimerControl SNVT_lev_disc - ST_OFF ST_ON ST_OFF ST_OFF (0) = Timer not active ST_LOW (1) = Timer active when

closing only ST_MED (2) = Timer active when

opening only ST_HIGH (3), ST_ON (4) = Timer

active in both directions

37 nviTimerOnTime SNVT_time_f s 1.0 10.0 1.0 Timer ON Time

38 nviTimerOffTime SNVT_time_f s 1.0 100.0 10.0 Timer OFF Time

39 nviTmrStrtPosOpn SNVT_lev_percent % 0.0 100.0 100.0 Timer stop position, opening direction

40 nviTmrStrtPosCls SNVT_lev_percent % 0.0 100.0 100.0 Timer start position, closing direction

41 nviTrqLimOpening SNVT_lev_percent % 0.0 100.0 75.0 Torque limit value, opening direction. Exceeding this value will trigger an alarm

42 nviTrqLimClosing SNVT_lev_percent % 0.0 100.0 75.0 Torque limit value, closing direction. Exceeding this value will trigger an alarm

43 nviTrqAlrmBypass SNVT_lev_percent % 1.0 8.0 5.0 Torque alarm bypass distance, in % of full range from both ends

45 nviReset SNVT_lev_disc ST_OFF ST_ON ST_OFF ST_OFF (0) = No action ST_MED (2) = Force factory default ST_ON (4) = Reset: force new reading

of data from base card



Table 4 – ESD Configuration

Value of nviESDAction.state ESD Action 0: HVO_OFF Not Active

1: HVO_POSITION Go to the position specified in nviESDAction.percent

2: HVO_FLOW_VALUE Not used

3: HVO_FLOW_PERCENT Not used

4: HVO_OPEN Open valve

5: HVO_CLOSE Close valve

6: HVO_MINIMUM Not used

7: HVO_MAXIMUM Not used

8 - 0xFE: (invalid) Stay put

0xFF: HVO_NUL Stay put

C.4 Maintenance variables These data are related to the actuator maintenance, are exchanged only with the DCM and are available at a DCM specific screen; they are not propagated to the MODBUS interface. nv # nv name nv type Units Min Max Default

value Comments

46 nviComissDate SNVT_time_stamp - - - - Date of the field installation

47 nviMaintDate SNVT_time_stamp - - - - Date of the next scheduled maintenance intervention.

48 reserved SNVT_lev_percent



51 nvoCycleCounter SNVT_count_f - 0.0 224-1 - Number of combined Contactor Cycles



C.6 Factory commissioning variables (Read only) These data are related to the actuator maintenance, are exchanged only with the DCM and are available at a DCM specific screen; they are not propagated to the MODBUS interface. nv # nv name nv type Comments 52 nviActuatorSize struct Actuator size, 24 characters

53 nviSerialNumber struct Serial number, 16 characters

54 nviMotorSupply struct Motor supply, 16 characters

55 nviNamePlate struct Name plate. See table 5 below

Table 5 – Actuator Nameplate Bit Field Name Field Type Comments

0-3 HardwareRev char[4] Hardware revision, 4 characters

4-7 SoftwareRev char[4] Software revision, 4 characters

8-11 NominalTorque float_type Nominal Torque

12-15 ActuatorRPM float_type Actuator RPM

16-22 ConfigTime SNVT_time_stamp Date of Factory Commissioning

23 IsThreePhase boolean 0= Single Phase 1= Three Phase



C.7 Fault detection function configuration These data are related to the function that controls the integrity of the communication loop. These data are exchanged only with DCM and are available at DCM specific screen; they are not propagated to MODBUS interface. nv # nv name nv type Comments 57 nviFdiCmd SNVT_count FDI Commands: see Table 6 below.

58 nviFdiConfig struct FDI Configuration: see Table 7 below.

Table 6 – FDI command Value Command Description 1 Disable Disables FDI algorithms for the particular node and resets the node's

relays to their default state.

2 Enable Enables FDI algorithms for the particular node and awaits proper communication to trigger the FDI system.

3 Disable All Relays a Disable Command to all nodes connected to the network.

4 Enable All Relays an Enable Command to all nodes connected to the network.

5 Connect Network A Manual switch side A from terminator to network.

6 Disconnect Network A Manual switch side A from network to terminator.

7 Connect Network B Manual connect to Network B.

8 Disconnect Network B Manual disconnect from Network B.

Table 7 – FDI configuration Field Name Field Type Value Description

Node Id integer 0 Passive node

1 Master Node connected to Network A

2 Master Node connected to Network B

AddrMode integer 1 All the nodes in the network make a simple loop

2 Reserved

3 The nodes in the network are grouped in different loops

4 Reserved

TimerInt unsigned long - This parameter controls the speed of the fault detection process and is expressed in time units referred to the internal clock. A lower value increases the network traffic by the FDI nodes, while a higher value decreases network traffic. Typical values fall in the range of 200 to 400.



APPENDIX D: PERFORMANCES

D.1 DCM Memory Capacity In the standard version the DCM memory is suitably sized to manage up to 300 ICON or ICON2000 actuators.

D.2 Field bus Connections As for the nodes connection mode to field bus, the physical limitations of a high-speed data transmission line must be considered. For this reason the maximum capacity can only be obtained by a suitable connection which must follow the following general rules: Single station with non-redundant bus

Bus max length:

Nodes per segment:

Max number of Repeaters:

Max number of node in the field:

2500mt (w/o Repeater) 60 (w/o Repeater) 3 240

Single station with redundant bus

Bus max length:

Nodes in the loop:

Max number of nodes per

loop: Max number of Repeaters:

Max Bus length:

Max number of nodes in the field:

1400m (w/o Repeater) 60 (w/o Repeater) 120 3 (external) 5600m 120

NET 1 NET 2


LONWORKS Interface


T

NET 1 NET 2


LONWORKS Interface




Master and Slave Stations with redundant bus

Bus max length:

Number of nodes:

Max number of

nodes:

Max number of Repeaters:

Bus max length:

Max number of

nodes in the field:

1400m (w/o Repeater) 60 (w/o Repeater) 120 3 (external) 5600m 120

Master and Slave Stations with redundant bus on various loops

For each loop:

Max length:

Number of nodes:

Max number of nodes per loop:

Max number of

repeaters:

Max Loop length:

Total system Max number of

loops

Max number of nodes in fields:

Total bus length:

1400m (w/o Repeater) 60 (w/o Repeater) 120 3 (external) 5600m 18 300 25 km (w/o Repeater)

Output Module LOOP A

IN NET 1 IN NET 2

LOOP B

NET 1 NET 2

NET 1 NET 2


LONWORKS Interface


LAN

NET 1 NET 2


LONWORKS Interface


NET 1 NET 2

NET 1 NET 2


LONWORKS Interface


LAN

NET 1 NET 2


LONWORKS Interface




D.3 Field bus Communications The nature of field bus communications, according to the LONWORKS protocol, makes the system very quick in acquiring the signals from the field and in transmitting controls. Status transmissions from on-field actuators is made by the actuators themselves when a variation occurs without any polling from the Master Station; there is anyway a periodic transmission, always generated by on-field devices, which refreshes the DCM image of the field. The DCM sends all controls directly and explicitly. The field bus implemented by ICON and ICON2000 actuators uses FTT-10A transceivers with a transmission speed of 78Kbps independently of the number of actuators connected and of the total length of the bus. The following times were recorded: Launch time of a control: 200 msec this is calculated from the moment the control

appears on the MODBUS bus to the moment the control is performed by the actuator

Acquisition time of a signal: 600 msec this is calculated from the moment the signal

is sent on the LonWorks bus to the moment the same signal is available to the MODBUS interface. The MODBUS scan time of the DCS must be added to this time, but this does not depend on the DCM.

D.4 Reset Time after Bus Interruption The communication loop integrity check system is made by a mixed system, which leaves the NETx nodes to check field bus continuity and the DCM to research the fault. The fault is detected by the NETx nodes after the interruption lasts for a certain programmable lapse of time, obtained by setting parameters Addr Mode and Timer Int of NETx nodes, as described in the table at paragraph 5.4.1: ‘NETH and NETT Nodes’. It is advisable to set these parameters so as to obtain a longer waiting time than 5 seconds to avoid all false signals of interrupted bus. Once the fault has been detected, the DCM restores connection. The necessary time to localize and isolate the fault by inserting terminators in the closest actuators is in function of the number of actuators connected to the loop. By means of an optimised algorithm, this time is anyway always less than 6 seconds.

D.5 Time for Control Switching between Master and Slave Units A redundant system, with two DCM stations in back-up, allows the control system to go on working even though the main DCM is no longer operational. The Slave DCM controls the behaviour of the Master DCM by monitoring several communication parameters through the LAN line. When the Master DCM shows any signs of bad performance, the Slave DCM makes a series of attempts to restore the Master station; if these attempts are not successful and performance is still bad, the Slave DCM Slave takes control in 600 msecs time.

.

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Master station specification for user’s function (5578-E4-VP-IU-604-030)

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