PET STAR 4 CMC TECHNICAL REFERENCE MANUAL

Transcription

1 PET STAR 4 CMC TECHNICAL REFERENCE MANUAL Date of Issue : August 2004

2 PET STAR 4 CMC MANUAL CCN Copyright Notice Copyright 2004 Ingersoll - Rand Company THIS MANUAL IS SOLD "AS IS" AND WITHOUT ANY EXPRESSED OR IMPLIED WARRANTIES WHATSOEVER. Printing Date: August 2004 Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air applications. Ingersoll-Rand does not approve specialized equipment for breathing air applications and assumes no responsibility or liability for compressors used for breathing air service. Date of Issue: August 2004

3 PET STAR 4 CMC MANUAL CCN Table of Contents References 4 General - CMC Panel 5 Control Methodology 6 Three Step Regulation 6 Auto Start / Stop Operation 6 Constant Speed Operation 6 Oil System Control 6 Auxiliary Oil Pump Light (systems with auxiliary oil pumps) 6 Standard 7 Stage Data Package 7 Cooling Fan 7 Alarm Horn 7 Running Unloaded Shutdowm Timer 7 Water Solenoid Post Run Timer 7 Panel Mounted Wye Delta Starter 7 NO Contact for Remote Indication of Common Alarm and Trip 7 Power Regulating Constant Voltage Transformer 7 Automatic Starting 8 Control Electrical Package 8 Options 8 Enclosures 8 NEMA 4 (IP 65) 8 Fused Control Power Disconnect 9 Panel Mounted Soft Starter 9 Remote Start and Remote Stop Hardwired 9 Communications 9 Protection and Monitoring 10 Analog Functions 10 Digital Functions 10 Compressor Operating Methodology 12 Stopped 12 Waiting 12 Not Ready 12 Ready 12 Starting 12 Date of Issue: August

4 PET STAR 4 CMC MANUAL CCN Unloaded 13 0% Load 13 50% Load % Load 13 Coasting 13 User Interface 14 OUI (Operator User Interface) 14 Command Keys 15 System Folder 18 Info Folder 19 Settings Folder 23 General Sequence Of Operation 27 Indicator, Switch and Light Layout 28 Lights 28 Push Buttons 28 Switches 28 Selector Switches 28 Troubleshooting 30 Troubleshooting Tree 30 Troubleshooting Example 31 I / O System 32 Temperature Monitoring System 32 Pressure Monitoring System 39 Digital Input System 43 Control Power System 45 Controller Problems 48 Communication 50 Human Machine Interface (HMI) System 50 Direct CMC Communications with RS422/ The CMC Modbus Interface 51 The CMC- DF1 Interface 70 Documentation 97 System Information 97 Base Control Module 99 Operator User Interface Module 102 Universal Communication Module (Optional) 106 Glossary 114 Date of Issue: August

5 PET STAR 4 CMC MANUAL CCN References The following references were used in creating this document. Reading this material is highly recommended for a more detailed understanding of specific control modes and control panel functions. CMC TECHNICAL REFERENCE MANUAL-CMC2003- PART NUMBER Revision B, Version 3.10, Ingersoll-Rand Company, March 24, NOTE NOTICE This manual is intended to provided the operator with information on the CMC control panel as it is configured for use on the PET Star 4 products. Additional information can be found in the reference above. Date of Issue: August

6 General - CMC Panel The CMC panel is the microprocessor-based control and monitoring system for PET Star 4. The CMC handles compressor pressure control and monitoring functions; as well as, control of auxiliary equipment such as the main motor starter and auxiliary oil pump. The CMC panel has a custom designed computer board called the Base Control Module (BCM). This board has a micro controller and memory chips that tell the rest of the panel what to do for the various input pressures, temperatures. All hardware for data analysis, number of input and output (I/O) points and system memory are optimally selected for accurately controlling and protecting PET Star 4 compressors. Features of the CMC system are: Ease of use... only twelve buttons to push on the operator OUI! Multiple function, 240 x 128 pixel graphic LCD display-to-display data and operating status Optional port for communicating to the Air System Controller (ASC), Air System Manager (ASM), or other Distributed Control Systems (DCS) via MODBUS protocol. Optional reduced voltage motor soft starter included in panel for some sizes. NOTICE For the purpose of consistency and clarity, all of the descriptions and examples that follow refer to "air" for the more generic "gas". Date of Issue: August

7 Control Methodology Three Step Regulation Compressor loading and unloading is governed by the UNLOAD PRESSURE and the LOAD PRESSURE set by the operator in the panel. The CMC compares the measured system pressure via a pressure transducer mounted in the air system downstream of the compressor discharge, typically in the air receiver. When the system pressure reaches the UNLOAD PRESSURE setting, the regulation solenoid valves are de-energized, allowing the control air pressure to act on the inlet valve unloaders. When the system pressure reaches the LOAD PRESSURE setting, the regulation solenoid valves are energized, venting the control air pressure from the inlet valve unloaders and allowing the compressor to load. Auto Start / Stop Operation Compressor will operate in an unloaded state for an operator specified time (UNLOAD TIME) after system pressure reaches UNLOAD PRESSURE and before LOAD PRESSURE is reached. When the UNLOAD TIME expires, the controller will issue a stop command and the compressor will coast to a stop and enter a Ready to Start state. Once LOAD PRESSURE is reached, the compressor restarts automatically without operator intervention. This is the preferred method in which to operate the compressor Constant Speed Operation Compressor will operate in an unloaded state between UNLOAD PRESSURE and LOAD PRESSURE indefinitely without automatically issuing a stop command. Operation in this mode is acceptable if the operator knows the compressor has short unloaded operating times and the application demands that the compressor reach full load operation without the added time involved in starting the compressor. Oil System Control Auxiliary Oil Pump Light (systems with auxiliary oil pumps) The auxiliary oil pump light is illuminated whenever the auxiliary oil pump contactor is engaged and the auxiliary oil pump is running. The auxiliary oil pump operates whenever the selector switch is in manual setting. Manual mode AOP operates whenever the selector switch is in manual mode setting and will continuously until the stop command is executed from the control panel. Auto mode AOP operates whenever the control supply power is ON. AOP will run continuously. Date of Issue: August

8 Standard Stage Data Package For monitoring of interstage pressure and temperatures, the Stage Data Package can be added. As standard, the CMC comes with temperature readout, alarm and trip for the next to last compression stage and compressor discharge pressure indication. When selected, each stage gets temperature and pressure measurements on the upstream & downstream side of each stage's cooler. For compressors without built-in aftercoolers, the last stage diffuser temperature is measured. Each temperature has readout, alarm and trip capability while the pressures are readout only. Cooling Fan The cooling fan is supplied on all standard CMC enclosures. A filter and gasket are added to attain a NEMA 12 rating. Alarm Horn The optional alarm horn sounds any time there is an alarm or trip situation. The horn output will pulse for an alarm and remain constant for a trip. This allows the operator to distinguish between each fault type without viewing the OUI. The horn silence pushbutton is located on the CMC faceplate to silence any audible devices connected to the CMC board. Running Unloaded Shutdown Timer The intent of this option is to save energy by shutting the compressor off during extended periods of unloaded operation. When the running unloaded shutdown timer is enabled with the RUNNING UNLOADED SHUTDOWN TIMER DISABLED/ENABLED selector switch, the auto-dual control mode should be selected, this provides for automatic unloading of the machine during periods of low demand. Water Solenoid Post Run Timer This optional panel function is used to shut off water flow to the air and oil coolers after the compressor is stopped. It is accomplished by sending a signal to close the solenoid operated water valve(s). Panel Mounted Wye-Delta Starter Main motor starter enclosed in the CMC panel. NO Contact for Remote Indication of Common Alarm and Trip A normally open contact for individual remote indication closes whenever an alarm or trip occurs. This allows a customer to have remote indication of compressor alarm, trip or both. Power Regulating Constant Voltage Transformer If the electrical power supplied to the CMC varies more than ten percent, this transformer must be added to bring the voltage within the specification requirements. Date of Issue: August

9 Automatic Starting NOTICE Most electric motors are only rated for three cold starts or two hot start per hour. It is the operator s responsibility not to exceed the electric motor s limitation. The control system allows the compressor to be started when the compressor is ready, not the motor. Remote start and stop through hard wiring to the compressor control panel, communicating through the MODBUS port via RS422/485,With each of these options a REMOTE COMMUNICATIONS DISABLED/ENABLED or REMOTE FUNCTIONS DISABLED/ENABLED, selector switch is provided on the device plate with a REMOTE ENABLED light. Since each option performs basically the same function, only one should be purchased for a single CMC. The specific method selected depends upon the application. Control Electrical Package The Control Electrical Package consists of a Control Transformer, Auxiliary Oil Pump Starter, Oil Heater Contactor(s) and Transient Voltage Surge Suppressor. This option allows the customer to bring a single source of electrical power to the compressor to run the entire compressor package accessories; thereby, making compressor installation easier. Options This section details the various standard options that are available for the CMC. Some of the options listed are provided standard on some models, and will be indicated as such. Enclosures The CMC has three panel enclosures available; NEMA 12 (IP 54) which is standard, and optional NEMA 4 (IP 65) and NEMA 4X (IP 65). The panel is machine mounted. All electrical devices are mounted and wired where practical. NEMA 4 (IP 65) This optional enclosure type is applied for most outdoor applications. Indoor applications that are subject to hose washing would also apply to this standard. NEMA defines this rating as "... intended for indoor and outdoor use primarily to provide a degree of protection against windblown dust and rain, splashing water, and hose directed water; and to be undamaged by the formation of ice on the enclosure. They shall meet hose down, external icing, and rust-resistance design tests. They are not intended to provide protection against conditions such as internal condensation or internal icing." Date of Issue: August

10 The standard panel enclosure is replaced with a new box that meets the above requirements. The User Terminal vinyl overlay and sealing bezel is door mounted and allows direct interface with the environment. NEMA 4 rated lights; switches and buttons are mounted directly through the panel door. A panel space heater and Vortex Tube Cooler are added to accommodate changes in ambient temperatures. Fused Control Power Disconnect As a safety precaution, this option removes power from the panel before the door is opened. By turning the rotary door handle, the panel power is terminated. If the disconnect is to include fuse size provisions for the main motor starter, additional information is required. The disconnect would have to be mounted external to the panel enclosure. The short circuit capacity, maximum ground fault, motor full load amps, motor locked rotor amps and motor voltage must be known to size the disconnect properly. Pricing varies depending upon the size, amp rating of the fuse, which is required for protection. Panel Mounted Soft Starter Main motor starter enclosed in the CMC panel. Standard for Petstar 1260 thru Soft starters will only load at the end of the voltage ramp time and do not require a start timer. Remote Start and Remote Stop Hardwired When this option is purchased, two digital inputs are configured on the CMC Base Control Module, one for remote start and one for remote stop. Remote Start Digital Input This input is driven by a momentary contact closure of at least 120 milliseconds. For the start to proceed the panel power must be on, the compressor must be in the Ready state (all utilities must be running and permissive functions satisfied) and the REMOTE FUNCTIONS DISABLED/ENABLED selector switch is in ENABLED mode prior to energizing the input. Remote Stop Digital Input This input is driven by a maintained contact closure. The remote stop input is always active; that is, the remote stop can be initiated regardless of the REMOTE FUNCTIONS DISABLED/ENABLED selector switch position. Communications Remote starting and stopping can be accomplished through the MODBUS communication port in various ways. See the section on Communications that follows for these options. Again, panel power must be on, all utilities must be running and permissive functions satisfied in order for the start-up to proceed. Date of Issue: August

11 Protection and Monitoring Each CMC base module has twenty-three analog inputs, sixteen digital inputs, four analog outputs and sixteen digital outputs for control, protection and monitoring. These input functions provide the CMC with information about the compressor. The CMC board uses the output functions to communicate to the user and perform actions like starting the compressor and turning on the auxiliary oil pump. All of these inputs and outputs are required to interface physical actions to and from the electronics. Analog Functions An analog function is one in which an electrical signal represents a specific pressure or temperature. As these inputs and outputs fluctuate, the electrical signal to and from the microcontroller board also fluctuates proportionally to the amount of change. Analog Inputs Twenty-one grounded and two floating analog inputs are used for protection, monitoring and control. Each input used for protecting the compressor is programmed for alarm and trip indication. Each of these functions is pre-programmed with the function title, engineering units, range, alarm and trip values, so no configuration is required upon receipt by the customer. The CMC uses pressure transmitters to measure pressure, resistance temperature detectors (RTD) and transmitters to measure temperature The CMC logic used for the protective alarm and trip functions is as follows: if the actual value of the input is greater than or equal to the alarm or trip value, indicate the condition. This logic is used for all inputs except, low oil pressure and temperature where the logic is reversed. Analog Outputs Analog outputs are not used on PET Star 4 products. Digital Functions A digital function is one in which the presence of an electrical signal indicates ON or YES, and the lack of that signal represents OFF or NO. This is analogous to a light switch that has only two states, ON or OFF. The term "discrete" is also used instead of digital in many instances. The term that will be used throughout this documentation shall be digital. Digital Inputs The sixteen digital inputs provide status of field switches. Emergency Stop is standard. Any of these inputs can be configured as an alarm or trip. All inputs operate on 24 VDC power. Digital Outputs The sixteen digital outputs can operate on 120 VAC, 60 Hz, single-phase power or 24 VDC power. Date of Issue: August

12 NOTICE PET Star 4 products can be configured for a variety of analog and digital functions depending on the PET Star 4 model and the configuration of options. Every CMC panel comes with a wiring diagram tailored specific to that configuration. Consult the wiring diagram and the compressor Process and Instrumentation Diagrams (P&I Diagrams) for details specific to the serial number of the compressor for a more thorough description of all the analog and digital functions. Date of Issue: August

13 Compressor Operating Methodology In the following description of compressor operation, the term state is used to indicate what the compressor is doing, or mode of operation, at any given time. These operating states exist in a hierarchy. All other states exist at a level below these two states. Compressor Operating States Motor Driven Packages + Compressor + + Stopped Waiting Not Ready Ready Starting Unloaded Loaded 0% Load 50% Load 100% Load Unused Unused Coasting Stopped This state implies that the compressor is or NOT rotating. It is important to note that this is an implication only. If the instrumentation is not working properly or the system is setup improperly, the compressor could be rotating. Waiting After the panel power is energized, the controller starts the Waiting Timer and does not allow further User operation until after the timer expires. Not Ready When in this state, the compressor is Not Ready To Start. This state is entered when the Waiting Timer has expired and any time that a compressor trip has been identified or a stop command has been issued. A very common and quite often overlooked reason for the compressor being Not Ready is when the Emergency Stop push button has been engaged. This state can exist indefinitely. Ready Similar to the previous state, this state could be redefined as Ready to Start. This state is entered when all compressor permissive functions have been satisfied. This state can exist indefinitely. Starting Any time after the compressor is ready and a start command is given, this state is entered. The goal for this period is to get the compressor to rated speed and running unloaded. Starting is allowed for only the Start Timer period. Date of Issue: August

14 This state exits only after the Starting Timer has expired. THE COMPRESSOR IS ALWAYS STARTED UNLOADED. When the compressor is operated with no system air pressure in the receiver, air is applied to the inlet valve unloaders via the instrument air solenoid valve. The instrument air solenoid valve is piped up to a separate air system to provide air for the inlet valve unloaders. On exit of Starting, the compressor will return to the mode that it was in the last time it ran. For example, typical operation implies that prior to stopping the compressor, the Unload key is pressed. If this occurred, then the compressor will remain in Unload after starting. If the compressor is was running and tripped, the compressor will automatically return to the Loaded mode on exit of the Starting state. The User may also press the Load or Unload key prior to pressing the Start key to force the compressor to into either post-starting state. Unloaded The compressor is in this state after a start (and Load Selected is not in effect) or when the user issues an unload command. 0% Load The load command is active and the present demand requires both regulation solenoid valves to be de-energized. The de-energized solenoid valves allow control air pressure to reach the inlet valve unloaders which in turn unloads the compressor. 50% Load The load command is active and the present demand requires one of the regulation solenoid valves to be de-energized. The de-energized solenoid valve allows control air pressure to reach half of the installed unloaders which in turn partially unloads the compressor. 100% Load The load command is active and the present demand requires the regulation solenoid valve to be energized. The energized regulation solenoid valve vents the control air pressure on inlet valve unloaders to successfully load the compressor. Coasting When a trip or any stop command is issued and the compressor is running, the motor will be de-energized and the compressor will begin to coast to a Stopped state. This state will remain as long as the adjustable Coast Timer is in effect. At the end of the timer, the compressor will enter either the Ready or Not Ready state. WARNING Failure to set the Coast Timer for a period greater than or equal to the actual coasting time can result in compressor damage. Date of Issue: August

15 User Interface OUI (Operator User Interface) Basic Operator User Interface skills can be obtained by reading the CMC Technical Reference Manual documented in the Reference section. User interface is defined as the means by which people interact with the compressor control system. The standard configuration of the CMC has two components of the user interface. They are the OUI and the device plate. The key component of "easy to use" is that there are only twelve buttons to press on the OUI and four buttons, lights, and switches on the device plate. The CMC OUI consists of six command buttons (Start, Stop, Load, Unload, Acknowledge and Reset), four navigation keys (Up, Right, Left and Down), an Edit mode selection key (Enter) and a Contrast key. These keys in conjunction with the 240x128- pixel graphics display make up the user interface to the compressor. The bezel that surrounds the OUI ensures that the NEMA 4 rating is maintained for the OUI. CENTAC Microcontroller SYSTEM INFO SETTINGS System Pressure Load Pressure Setpoint Pressure Set Setpoint Running Hours 1000 Loaded Aug :39:00 Load Selected Remote 1/8 Date of Issue: August

16 PETS STAR 4 CMC MANUAL CCN Command Keys These keys command the compressor to perform actions as specified in the following table. When any of these keys are pressed the action will be logged in the event log. Key Name Function Silences the optional horn or Acknowledge acknowledges an alarm. Reset Start Stop Load Unload Clears all trip latches. Required to be pressed after a trip condition to restart the compressor. Starts the compressor. Stops the compressor. This button should be pressed instead of the E-Stop for normal operation. Engages Modulate or Auto dual control mode. Unloads the compressor. Enter Key - Display Operating Mode The Enter key toggles the display between the NAVIGATION mode and the EDIT mode. Navigation Keys The arrow keys for Up, Right, Left and Down perform differently depending upon the current display-operating mode. FOLDER NAVIGATION To move among the tabbed folders, press the RIGHT or LEFT key. The folder list is circular; that is, when the SYSTEM folder is displayed and the LEFT key is pressed, the SETTINGS folder becomes active. The same is true when the SETTINGS folder is displayed and the RIGHT key is pressed, the SYSTEM folder becomes active. PAGE NAVIGATION To move among each folder s pages, press the UP and DOWN keys. The page list is also circular. So, when page 1/4 (pronounced page 1 of 4) is active and the UP key is pressed, page 4/4 becomes active. Also, when page 4/4 is active and the DOWN key is pressed, page 1/4 becomes active. The current page for a folder is persistent. For example, if you begin on the SYSTEM folder page 2, change to the INFO folder and return to the SYSTEM folder, page 2 will be the page displayed. Date of Issue : August

17 Contrast Key This key changes the contrast of the backlight for the graphic LCD display. Pressing this key steps among each of the thirty two contrast levels. When stepped to the thirty second level, pressing the key again returns to the first contrast level. Graphic Display The 240x128-pixel graphic display allows us to provide a flexible interface between the user and the compressor. The display has three distinct regions as shown in the diagram below. Folders Page Status Bar SYSTEM System Pressure Load Pressure Setpoint INFO Loaded SETTINGS Set Pressure Setpoint Running Hours Aug :39:00 Load Selected Remote 1/8 Page Number Compressor Operating State Compressor Control Location Compressor Status Graphics Display Area Definitions Folder and Page In the design of this system, it is important to provide much of the information required for operating and troubleshooting the compressor. The tabbed folder with multiple pages metaphor has been used to reduce the complexity of a traversing at least sixteen pages of information. For the standard design, the maximum number of keys required to get to any of the sixteen pages is six. The SYSTEM folder provides information about the compressor system, the INFO folder gives various types of information about the unit, the SETTINGS folder is used to perform compressor setup. Status Bar The Status Bar provides four distinct types of information (Compressor Operating State, Compressor Status, Compressor Control Location and Page Number). This region is always visible from any folder and page combination. This Field is displayed in large text so that the operator can determine the compressor s current operating state at a glance. See Section titled Compressor Operating Methodology for a list of the messages provided. The Compressor Status Field messages are Trip, E-Stop (emergency stop button pressed), RMT-Stop (a remote stop has been pressed, an optional feature), Start Disabled (an optional permissive start condition has not been satisfied), Alarm, Unload Selected (the compressor will stay in Unload after Starting has been completed), and Load Selected (the compressor will go to Load after Starting has been completed). The Compressor Control Location Field messages are Local, Remote (remote hardwired commands i.e. start, stop, load, unload etc.), Network (MODBUS, DF1 or Date of Issue : August

18 ASC communication with a UCM) and Remote/Network (both Remote and Network). This indication is provided to indicate to the operator that a remote location is in control of the compressor and the compressor may start, stop, load, unload, etc. without the local operator initiating any commands. These three fields combine to provide the operator with the necessary information to create a cursory determination of the status of the compressor. When a more thorough determination is required, the operator can get additional detail by looking through the other pages in the system. The Page Number indicates the current page for the current folder with the number of pages in the folder. The number of pages is given so that the user always knows where he is in the system. Navigation Mode Navigation mode is active when a folder name (SYSTEM, INFO, SETTINGS) is highlighted. Edit (Set point Changes) Mode Edit mode is activated by pressing the ENTER key. In Edit mode one can change Set points for a page. Once in this mode, the highlight will move from around the folder name to the item to be changed. Use the Right and Left arrow keys to move among the changeable items and the Up and down arrow keys to change the value of the item. When changes are complete, press the Enter key again to return to Navigation mode. Scroll Mode Scroll mode is activated by pressing the ENTER key when a folder name INFO is highlighted and the Event Log or the Routine Start / Stop page is visible. The Scroll mode is used to page through the event log. To move among the pages, press the UP or DOWN keys. To deactivate the Scroll mode, press the Enter key. Date of Issue : August

19 SYSTEM Folder The SYSTEM folder provides information about the compressor system. The number of pages in this folder is at SYSTEM System Pressure Motor Load Pressure Setpoint Set Pressure Setpoint INFO Loaded SETTINGS Running Hours Aug :39:00 Load Selected Remote 1/8 System Folder Page 1: System Pressure SYSTEM SYSTEM INFO INFO Digital Inputs Loaded SETTINGS Press Temp Stage Stage 2 Inlet 92.0 Stage Stage 3 Inlet Stage Stage 4 Inlet Stage Loaded SETTINGS Starter Feedback E-Stop Remote Communication Enabled Auxiliary Oil Pump in Manual Cooling Water SV in Manual least four; but could be more with special analog options purchased, or for compressors with three stages or more. This page shows the main compressor operating parameters, running hours, date and time. The System Pressure is the pressure reading in the customer s air header and Load Pressure Set point is the value at which the compressor will reach 100% load when the system pressure is less than or equal to the set point. Set pressure set point is the value at which the compressor will reach 0% load when the system pressure is greater than the set point. The Analog Input page provides the actual value for each stage pressure, temperature and oil pressure and temperature. If additional analog inputs have been purchased, it is likely that an additional page or pages will be added. The units are as defined by the Settings page. There are no editable set points on this page. The Digital Input page shows the current state of the digital (discrete) inputs for the system. The Load Selected Remote 2/8 Load Selected Remote 4/8 System Folder - Pages 2,4: Analog/Digital Inputs number of inputs will vary depending upon the number of optional inputs purchased. A check in the box to the left of the text indicates a TRUE condition, whereas, no check indicates a FALSE condition. For example, a check mark in the E-Stop Pressed boxed means that the Emergency Stop push button has been pressed. It is possible to have multiple Digital Input pages. Date of Issue : August

20 SYSTEM INFO Loaded SETTINGS Digital Outputs Auxilary Pump running Trouble Light Horn Remote Functions Enabled 1M Starter Relay 2M Contacting Relay 1S Shorting Relay Load Selected Remote 7/8 System Folder - Page 7: Digital Outputs Digital Output pages. SYSTEM The Digital Output page is similar to the Digital Input page except that it shows the current state of the digital (discrete) outputs for the system. The number of outputs will vary depending upon the number of optional items purchased. A check in the box to the left of the text indicates a TRUE condition, whereas, no check indicates a FALSE condition. It is possible to have multiple The SYSTEM folder s four pages give the current operating status for the compressor. The User is always within two keystrokes of all operating parameters. INFO Folder The INFO folder contains the OUI key map, the compressor event log, and the hour meters. There are no editable set points in this folder. The OUI key map will be the default page on power up. The keys are labeled in English and the local language, depending upon the current language selected. INFO SETTINGS Event Name Time Date 1 Dirty Oil Filter Alarm 09:18: Low Inst.Air PressAlarm 09:18: Stg.4 Rod Drop Alarm 09:18: Stg.3 Rod Drop Alarm 09:08: Stg.2 Rod Drop Alarm 08:58: Stg.1 Rod Drop Alarm 08:24: High M/Wdg.Temp.Alarm 08:23: Trip Remote 2/4 The Event Log details the last two hundred twenty four (224) events that have occurred. Each event has a date and time stamp. This Not Ready log will list all Alarms and Trips and provides first-out indication. Any time an Alarm or Trip is indicated on the Status Bar, the detail for that fault is included here. Info Folder - Page 2: Scrollable Event Log The event labeled as 1 is the newest event and 7 is the oldest event. For events that have identical Time and Date values, the order is still correct (newest to oldest, top to bottom). Once the list is full, each new event knocks off the last event. Pressing the Enter key to initiate Scroll Mode allows access to events 17 through 224. Scroll Mode is indicated by the reverse video of the event numbers. Each Down Arrow press displays the next seven events. An Up Arrow press will display the previous seven events. Any time a Trip occurs, the system will send the display to the first seven events. Date of Issue : August

21 Possible Events List Event Name Description Edit-C phone digit 1 The Phone Digit Value has been edited location from C Edit-C phone digit 2 The Phone Digit Value has been edited from location C. Edit-C phone digit 3 The Phone Digit Value has been edited from location C. Edit-C phone digit 4 The Phone Digit Value has been edited from location C. Edit-C phone digit 5 The Phone Digit Value has been edited from location C. Edit-C phone digit 6 The Phone Digit Value has been edited from location C. Edit-C phone digit 7 The Phone Digit Value has been edited from location C. Edit-C phone digit 8 The Phone Digit Value has been edited from location C. Edit-C phone digit 9 The Phone Digit Value has been edited from location C. Edit-C phone digit 10 The Phone Digit Value has been edited from location C. Edit-C phone digit 11 The Phone Digit Value has been edited from location C. Edit-C phone digit 12 The Phone Digit Value has been edited from location C. Edit-C phone digit 13 The Phone Digit Value has been edited from location C. Edit-C phone digit 14 The Phone Digit Value has been edited from location C. Edit-C phone digit 15 The Phone Digit Value has been edited from location C. Edit-C phone digit 16 The Phone Digit Value has been edited from location C. Edit-C phone digit 17 The Phone Digit Value has been edited from location C. Edit-C phone digit 18 The Phone Digit Value has been edited from location C. Edit-C phone digit 19 The Phone Digit Value has been edited from location C. Edit-C phone digit 20 The Phone Digit Value has been edited from location C. Edit-C phone digit 21 The Phone Digit Value has been edited from location C Edit-C phone digit 22 The Phone Digit Value has been edited from location C. Edit-C phone digit 23 The Phone Digit Value has been edited from location C. Edit-C phone digit 24 The Phone Digit Value has been edited from location C. Edit-C Post Water Time The Post Water Timer value has been edited from location C. Edit- L Post Water Time The Post Water Timer Value has been edited from location Local Edit-C Load Press SP The Load Press. Setpoint value has been edited from location C. Edit- L Load Press SP The Load Press. Setpoint value has been edited from location Local Edit- C Unload Press SP The Unload Press. Setpoint value has been edited from location C. Edit L Unload Press SP The Unload Press. Setpoint value has been edited from location Local Edit- C A/T Bypass Timer The A/T Bypass Timer has been edited from location x. Edit- L A/T Bypass Timer The A/T Bypass Timer has been edited from location Local. Power Down The Base Conrol Module Was De-energized. Power Up The Base Control Module Was Energized. Driver Trip Driver controller feedback was not received after a start command was issued. Starting Fail Drvier feedback was not received after a start command was issued. Loss of Motor Current Motor Current feedback was lost while running Auto Start An automatic start occurred. Auto Stop An Automatic Stop occurred. Reset (Local) A Reset has been executed from Location. Acknowledge (Local) A Acknowledge has been executed from Location. Load (Local) A Load command has been issued from local. Start (Local) A Start command has been issued from local. Stop (Local) A Stop command has been issued from local. Unload (Local) A Unload command has been issued from local. Acknowledge (Remote) A Acknowledge command has been issued from Remote Acknowledge (Comm) A Acknowledge command has been issued from Comm. Load (Remote) A Load command has been issued from Remote. Load (Comm) A Load command has been issued from Comm. Reset (Remote) A Reset Command has been issued from Remote. Reset (comm) A Reset Command has been issued from Comm. Start (Remote) A Start Command has been issued from Remote. Start (Comm) A Start Command has been issued from Comm. Stop (Remote) A Stop Command has been issued from Remote. Stop (Comm) A Stop Command has been issued from Comm. Unload (Remote) A Unload Command has been issued from Remote. Unload (Comm) A Unlaod Command has been issued from Comm. Autodual Mode Enabled The Autodual mode mode has been enabled. Const. Speed Mode Enabled Const. Speed Mode Enabled from Location. E-Stop Pressed Emergency Stop Pushbutton has been pressed. Compressor Started Compressor started from Location. Edit-C Auto Stop Timer Auto Stop Timer has been edited from Location C. Edit-L Auto Stop Timer Auto Stop Timer has been edited from Local. Date of Issue : August

22 Edit- C Month The Month Value for the data field has been edited from location C. Edit- L Month The Month Value for the data field has been edited from Local. Edit- C Day The Date Value for the data field has been edited from location C. Edit- L Day The Date Value for the data field has been edited from location Local. Edit- C year The Year Value for the data field has been edited from location C. Edit- L year The Year Value for the data field has been edited from location Local. Edit- C CT Ratio The CT Ratio Value has been edited from C. Edit- L CT Ratio The CT Ratio Value has been edited from Local. Edit- C Coasting Timer The Coasting timer value has been edited from C. Edit- L Coasting Timer The Coasting timer value has been edited from Local. Edit- C Starting Timer The Starting timer value has been edited from C. Edit- L Starting Timer The Starting timer value has been edited from Local. Edit- C Waiting Timer The waiting timer value has been edited from C. Edit- L Waiting Timer The waiting timer value has been edited from Local. Edit- C Time The time valuve has been edtied from C. Edit- L Time The time valuve has been edtied from Local. Edit C Aux. Pump Run Time Aux. Oil Pump run time has been edited from location C. Edit L Aux. Pump Run Time Aux. Oil Pump run time has been edited from location Location. Edit C Load Level Load Level has been edited from location C. Edit L Load Level Load Level has been edited from location Location. Edit C S2 Inlet Temp.HTV The S2 Inlet Temp. High Trip Value has been edited from C. Edit L S2 Inlet Temp.HTV The S2 Inlet Temp. High Trip Value has been edited from Local. Edit C S2 Inlet Temp.Trip The S2 Inlet Temp. Trip value hass been edited from C. Edit C S2 Inlet Temp. HAV The S2 Inlet Temp. High Alram Value has been edited from C. Edit L S2 Inlet Temp.HAV The S2 Inlet Temp. High Alarm Value has been edited from Local. High S2 Inlet Temp. Alarm The S2 Inlet Temp. High Alarm Value has been edited. Edit C S2 Temp. HAV The S2 Temp. High Alarm Value has been edited from C. Edit L S2 Temp. HAV The S2 Temp. High Alarm Value has been edited from Local. High S2 Temp. Alarm Stage 2 Temp. High Alarm Value has been edited. Edit C S2 Temp. HTV The S2 Temp. High Trip Value has been edited from C. Edit L S2 Temp. HTV The S2 Temp. High Trip Value has been edited from Local. High Stg. 2 Temp. Trip The S2 Temp. High Trip value has been edited. Edit C S3Inlet Temp. HTV The S3 Inlet Temp. High Trip Value has been edited from C. Edit L S3Inlet Temp. HTV The S3 Inlet Temp. High Trip Value has been edited from Local. High S3 Inlet Temp. Trip The S3 Inlet temp. High Trip value has been edited. Edit C S3 Inlet Temp. HAV The S3 Inlet Temp. High Alarm Value has been edited from C. Edit L S3 Inlet Temp. HAV The S3 Inlet Temp. High Alarm Value has been edited from Local. High Stg.3 Inlet Temp. Alarm The S3 Inlet Temp. High Alarm Value hhas been edited. Edit C S3 Temp. HAV The S3 Temp. High Alarm Value has been edited from C. Edit L S3 Temp. HAV The S3 Temp. High Alarm Value has been edited from Local. High Stg. 3 Temp. Alarm The S2 Temp. High Alarm Value has been edited. Edit C S3 Temp. HTV The S3 Temp. High Trip Value has been edited from C. Edit L S3 Temp. HTV The S2 Temp. High Trip Value has been edited from Local. High Stage 3 Temp. Trip The S3 Temp. High Trip Value has been edited. Edit- C S4 Inlet Temp. HTV The S4 Inlet Temp. High Trip Value has been edited from C. Edit- L S4 Inlet Temp. HTV The S4 Inlet Temp. High Trip Value has been edited from Local. High Stage 4 Inlet Temp. Trip The S4 Inlet Temp. High Trip Value has been edited. Edit- C S4 Inlet Temp. HAV The S4 Inlet Temp. High Alarm Value has been edited from C. Edit- L S4 Inlet Temp. HAV The S4 Inlet Temp. High Alarm Value has been edited from Local. High Stg. 4 Inlet Temp. Alarm The S4 Inlet Temp. High Alarm Value has been edited. Edit- C S4 Temp. HAV The S4 Temp. High Alarm Value has been edited from C. Edit- L S4 Temp. HAV The S4 Temp. High Alarm Value has been edited from Local. High Stg.4 Temp. Alarm The S4 Temp. High Alarm Value has been edited. Edit- C S4 Temp. HTV The S4 Temp. High Trip Value has been edited from C. Edit- L S4 Temp. HTV The S4 Temp. High Trip Value has been edited from Local. High Stage 4 Temp. Trip The S4 Temp. High Trip Value has been edited. Edit C Disch. Temp. HAV The Discharge Temp. High Alarm Value has been edited from C. Edit L Disch. Temp. HAV The Discharge Temp. High Alarm Value has been edited from Local. High Discharge Temp. Alarm The Discharge Temp. High Alarm value has been edited. Edit C Disch. Temp. HTV The Discharge Temp. High Trip Value has been edited from C. Edit L Disch. Temp. HTV The Discharge Temp. High Trip Value has been edited from Local. High Disch. Temp. Trip The Discharge Temp. High Trip Valuue has been edited. Edit C Oil Temp. HTV The Oil Temp. High Trip Value has been edited from C. Edit L Oil Temp. HTV The Oil Temp. High Trip Value has been edited from Local. High Oil Temp. Trip The Oil Temp. High Trip value has been edited. Edit C Oil Temp. HAV The Oil Temp. High Alarm Value has been edited from C. Edit L Oil Temp. HAV The Oil Temp. High Alarm Value has been edited from Local. High Oil Temp. Alarm The Oil Temp. High Alarm Value has been edited. Date of Issue : August

23 Edit C Water Temp. HTV The C/W Temp. High Trip Value has been edited from C. Edit L Water Temp. HTV The C/W Temp. High Trip Value has been edited from Local. High Water Temp. Trip The C/W Temp. High Trip Value has been edited. Edit C Water Temp. HAV The C/W Temp. High Alarm Value has been edited from C. Edit L Water Temp. HAV The C/W Temp. High Alarm Value has been edited from Local. High Water Temp. Alarm The C/W Temp. High Alarm Value has been edited. Edit C Water Temp. LAV The C/W Temp. Low Alarm Value has been edited from C. Edit L Water Temp. LAV The C/W Temp. Low Value has been edited from Local. Low Water Temp. Alarm The C/W Temp. Low Alarm Value has been edited. Edit C Water Temp. LTV The C/W Temp. Low Trip Value has been edited from C. Edit L Water Temp. LTV The C/W Temp. Low Trip Value has been edited from Local. Low Water Temp. Trip The C/W Temp. Low Trip Value has been edited. Edit C Stage 1 Temp. HAV The Stage 1 Temp. High Alarm Value has been edited from C. Edit L Stage 1 Temp. HAV The Stage 1 Temp. High Alarm Value has been edited from Local. High Stage 1 Temp. Alarm The Stage 1 Temp. High Alarm Value has been edited. Edit-C Stage 1 Temp. HTV The Stage 1 Temp. High Trip Value has been edited from C. Edit-L Stage 1 Temp. HTV The Stage 1 Temp. High Trip Value has been edited from Local. High Stage 1 Temp. Trip The Stage 1 Temp. High Trip Value has been edited. Edit-C Oil Press. LAV The Oil Pressure Low Alarm Value has been edited from C. Edit-L Oil Press. LAV The Oil Pressure Low Alarm Value has been edited from Local. Low Oil Press. Alarm The Oil Pressure Low Alarm Value has been edited. Edit-C Oil Press. LTV The Oil Pressure Low Trip Value has been edited from C. Edit-L Oil Press. LTV The Oil Pressure Low Trip Value has been edited from Local. Low Oil Press. Trip The Oil Pressure Low Trip Value has been edited. Edit-C WaterPress. LAV The Water Pressure Low Alarm Value has been edited from C. Edit-L WaterPress. LAV The Water Pressure Low Alarm Value has been edited from Local. Low Water Press. Alarm The Water Pressure Low Alarm Value has been edited. Edit- C Water Press LTV The Water Pressure Low Trip Value has been edited from C. Edit- L Water Press LTV The Water Pressure Low Trip Value has been edited from Local. Low Water Press. Trip The C/W Pressure Low Trip Value has been edited. Edit-C Stage 1 Press. HAV The Stage 1 Pressure. High Alarm Value has been edited from C. Edit-L Stage 1 Press. HAV The Stage 1 Pressure. High Alarm Value has been edited from Local. High Stage 1 press. Alarm The Stage 1 Pressure. High Alarm Value has been edited. Edit-C Stage 1Press. HTV The Stage 1 Pressure. High Trip Value has been edited from C Edit-L Stage 1Press. HTV The Stage 1 Pressure. High Trip Value has been edited from Local. High Stage 1 Press Trip The Stage 1 Pressure. High Trip Value has been edited Edit-C Stage 2 Press. HAV The Stage 2 Pressure. High Alarm Value has been edited from C. Edit-L Stage 2 Press. HAV The Stage 2 Pressure. High Alarm Value has been edited from Local. High Stg.2 Press. Alarm The Stage 2 Pressure. High Alarm Value has been edited Edit-C Stage 2 Press. HTV The Stage 2 Pressure. High Trip Value has been edited from C. Edit-L Stage 2 Press. HTV The Stage 2 Pressure. High Trip Value has been edited from Local High Stg.2 Press. Trip The Stage 2 Pressure. High Trip Value has been edited. Edit-C Stage 3 Press. HAV The Stage 3 Pressure. High Alarm Value has been edited from C Edit-L Stage 3 Press. HAV The Stage 3 Pressure. High Alarm Value has been edited from Local. High Stg. 3 Press. Alarm The Stage 3 Pressure. High Alarm Value has been edited. Edit-C Stage 3 Press. HTV The Stage 3 Pressure. High Trip Value has been edited from C Edit-L Stage 3 Press. HTV The Stage 3 Pressure. High Trip Value has been edited from Local. High Stg.3 Press. Trip The Stage 3 Pressure. High Trip Value has been edited. Edit-C Stage 4 Press. HAV The Stage 4 Pressure. High Alarm Value has been edited from C Edit-L Stage 4 Press. HAV The Stage 3 Pressure. High Alarm Value has been edited from Local. High Stg. 4 Press. Alarm The Stage 4 Pressure. High Alarm Value has been edited from C Edit-C Stage 4 Press. HTV The Stage 4 Pressure. High Trip Value has been edited from C Edit-L Stage 4 Press. HTV The Stage 4 Pressure. High Trip Value has been edited from Local. High Stg. 4 Press. Trip The Stage 4 Pressure. High Trip Value has been edited. Edit C Regulation Prs HAV The Regulation Pressure. High Alarm Value has been edited from C Edit L Regulation Prs HAV The Regulation Pressure. High Alarm Value has been edited from Local. High Regulation Alarm The Regulation Pressure. High Alarm Value has been edited. Edit C Regulation Prs HTV The Regulation Pressure. High Trip Value has been edited from C Edit L Regulation Prs HTV The Regulation Pressure. High Trip Value has been edited from Loal. High Regulation Press. Trip The Regulation Pressure. High Trip Value has been edited. Starter Failure Starter feedback was not received after a start command was issued. Starter Fault Closed Motor stopped but feedback present for 2 seconds. Stg.-1 Rod Drop Alarm The Alarm condition occurs when stage-1 Rod Drop High. Stg.-2 Rod Drop Alarm The Alarm condition occurs when stage-2 Rod Drop High. Stg.-3 Rod Drop Alarm The Alarm condition occurs when stage-3 Rod Drop High. Stg.-4 Rod Drop Alarm The Alarm condition occurs when stage-4 Rod Drop High. Dryer Fault Alarm The Alarm condition occurs when Dryer Fault. Dryer Fault Trip The Alarm occurs when dryer Trip. Date of Issue : August

24 This next page of the INFO Folder shows the hour meters and number of starts. Power On Hours is the time that the panel power has been on. The Running Hours are the amount of time that the compressor has been operating between all start and stop sequence. The Loaded Hours is the amount of time that the compressor has been running and not running unloaded. It can also be defined SYSTEM INFO Loaded SETTINGS Power On Hours 1200 Running Hours 1000 Loaded Hours 890 Number of Starts 23 BCM Ver: 3.10 Load Selected Remote 3/4 Info Folder Page 3: Hour Meters and Version as the number of hours that the compressor has been running in loaded condition. The Number of (Compressor) Starts is self-explanatory. NOTICE Most electric motors are only rated for three cold starts or two hot starts per hour. It is the operator s responsibility not to exceed the electric motor s limitation. The control system allows the compressor to be started when the compressor is ready, not the motor. The last item on this page is the Base Control Module Version number. This will be used by field personnel for quick reference to determine if newer software is available. SETTINGS Folder The SETTINGS folder is used for compressor setup. In this folder, the user will enter performance and control operating parameters, analog health monitoring settings for Alarm and Trip conditions, control mode selection, set point changes, password, user interface language. This folder is the primary location for editing set points. SYSTEM INFO SETTINGS Password * * * * Setpoint Changes Enabled Language and Units English degf amps psig English degc amps Kg/cm^2 The Password is used for determining whether Set point Changes can be made. The Password takes four numbers. If the Password is entered properly, Changes will be enabled (a check will be in the box); otherwise, they are disabled. This enabling and disabling applies to all changeable set points except, Pressure Set point, language selection and the Password, these items are always modifiable. Date,yyyy/mm/dd 2004/08/29 Time,hh:mm:ss 12:39:00 Load Selected Remote 1/6 Settings Folder - Page 1: Password, Language, Each control system is shipped with two languages and units of measure combinations. The first set is for the English language, pressures in units of PSIG, temperatures in units of degrees F.The other set will be localized for the customer. The default alternate language is English with Metric units. At present we can support only English Language. Date of Issue : August

25 The Date is set with three separate values (1) Year, including century (2) Month and (3) Day. The Time is also set with three values (1) Hour, (2) Minutes and (3) Seconds. Settings Folder Page 1 Edit Parameters Table Variable Units Minimum Value Maximum Value Step Size Password Digit dimensionless Date (Year) years Date (Month) months Date (Day) days Time (Hour) hours Time (Minute) minutes Time (Second) seconds The Control Mode Selection Page allows the User to select between the three standard control modes, Constant speed, Manual and Auto dual. This selection process is performed with the radio button selector. To change the selection, press the Up or Down arrow key. Constant speed: Compressor will run load & unload as long as there are no trips or stops. Even when the machine is running unloaded for more than 30 minutes it will continue to run. If customer selects this choice it is their responsibility that if the compressor is running unloaded for more than 30 minutes to stop it. SYSTEM INFO SETTINGS Auto Dual mode: Compressor will run load, unload. If it runs unloaded for 30 minutes, it will stop automatically. If the system pressure drops below the load set point, the compressor will restart automatically. (As per recommendation unloaded shutdown timer setting should not be less than 20 minutes & not more than 30 minutes.) Constant Speed Autodual Unload Delay Time, seconds 1 Manual 0% Load 50% Load 100% Load Loaded Load Selected Remote 2/6 Settings Folder Page 2: Control Mode Selection Manual mode: Compressor will run continuously in 0%, 50%, 100% capacity as per selection from CMC panel setting folder. If the customer selects this choice & under it he decides to run this unit in 0%(unloaded) condition then it is their responsibility to stop the compressor, if it runs in this condition for more than 30 minutes. NOTICE For Auto-Dual Mode Unloaded Shutdown Timer Setting Should not be less than 20 min. & should not be more than 30 min. Date of Issue : August

26 Settings Folder Page 2 Edit Parameters Table Variable Units Minimum Value Maximum Value Step Size Autodual Unload Delay Timer seconds CAUTION Manual should only be used for compressor setup. Starting Timer is the length of time prior to enabling the loading of the compressor. Typically, this time includes the starter transition time (Y-D time) and the Auxiliary pump shutdown. When this timer expires, the Auxiliary pump will turn off and the compressor is enabled for loading. SYSTEM INFO Loaded SETTINGS Starting Timer, seconds 20 Coasting Timer, seconds 30 Water Valve Time, seconds 60 AOP Press. Recovery Time,seconds 60 CT Ratio 60 Load Selected Remote 3/6 Settings Folder - Page 3: Miscellaneous Coasting Timer is the length of time that it takes for the driver to stop rotating. CT Ratio is the ratio of the current transformer primary to the secondary; i.e., if the CT primary winding is 300 and the secondary winding is 5, then the CT Ratio is 60. Water valve timer: This function is used to shutoff the water flow to compressor coolers after the compressor is stopped and preset time of the water valve timer elapses. AOP Pressure recovery timer: When Oil Pressure drops during running condition, AOP will come in line for preset time of AOP pressure recovery timer. Settings Folder Page 3 Edit Parameters Table Minimum Maximum Step Variable Units Value Value Size Starting Timer Seconds Coasting Timer Seconds CT Ratio Dimensionless Water Valve Timer Second AOP Pressure Recovery Timer Second Date of Issue : August

27 WARNING Failure to set the Coast Timer for a period greater than or equal to the actual coasting time can result in compressor damage. The Alarm and Trip Settings Page provides the means for changing the analog health monitoring values. The number of inputs varies depending upon the number of compression stages and optional inputs. Additional pages will be added as needed after this page. All line items are changeable for the Alarm and Trip set points. SYSTEM INFO Loaded SETTINGS Alarm Trip Stage 1 Temperature Stage 2 Inlet Temperature Stage 2 Temperature Stage 3 Inlet Temperature Stage 3 Temperature Stage 4 Inlet Temperature Stage 4 Temperature Load Selected Remote 4/6 Settings Folder - Page 4: Alarm and Trip WARNING Setting Trip values outside the range specified on the drawings can result in compressor damage. Date of Issue : August

28 General Sequence of Operation: To start and load a compressor follow steps 1, 2, 3 and 4 CENTAC Microcontroller 1 Press Reset 2 Look for "Ready" SYSTEM INFO SETTINGS System Pressure Load Pressure Setpoint Set Press Setpoint Loaded Aug-04 12:39 Load Selected Remote 1/8 3 Press Start 4 Press Load To unload and stop a compressor follow steps 5 and 6 5 Press Unload, wait 20 seconds 6 Press Stop Date of Issue : August

29 Indicator, Switch and Light Layout In addition to the CMC OUI there may be a variety of indicators, switches, and lights mounted on the control panel door. In conjunction with the CMC OUI these devices make up the User Interface for the CMC. A typical device layout consists of the following lights, push buttons, and selector switches. Lights The lights provided are the green CONTROL POWER ON light, which is integral to the CONTROL POWER OFF/ON switch, the amber AUXILIARY OIL PUMP RUNNING light and the red TROUBLE INDICATION, AOP O/L TRIP light. Push Buttons The red EMERGENCY STOP push button stops the compressor any time that it is pressed. This push button is used to initiate a stop in the case of an emergency. Switches The CONTROL POWER OFF/ON selector switch turns the panel power on or off. LOCAL/REMOTE SWITCH is used to switch from the local or remote network locations. Selector Switches Manual and automatic switches may be incorporated to allow the operator to test the function of package equipment such as the auxiliary oil pump, C/W SOV and system components such as dryers without having to start the compressor. Date of Issue : August

30 Setting the Start Time The Start Time is set to the transition time of a built-in Wye - Delta starter time of a customer supplied starter. CAUTION Damage to the starter contacts could result if starter transition occurs before the compressor is up to full speed. 1. Initially set the Start Time to 25 Seconds. 2. Stop the compressor. Allow compressor to coast to a stop. 3. On the OUI record the time and press the start button. 4. Calculate the difference between the two values and enter as the Start Time. Setting the CT Ratio Locate the CT and find the rating, which is typically printed, on the side of the CT. Divide the primary by the secondary and enter the value as the CT Ratio. Example: CT is printed with 600:5, the value entered is 120. Alarm and Trip Settings The values for temperature, pressure etc. alarm and trip set points are located on the electrical schematic. These values determine when the controller will indicate an alarm or trip condition. WARNING Setting Trip values outside the range specified on the drawings can result in compressor damage. Date of Issue : August

31 Troubleshooting The following procedures provide direction on troubleshooting the CMC System, control panel, and associated instrumentation. Faults are either Event Logged, which means the fault is displayed in the INFO Folder on the OUI, or Non-Event Logged. The distinction helps to expedite the troubleshooting process. When a control system fault is suspected, the following diagram is used to categorize the fault. The section following the diagram breaks each category down into specific items, which can cause a particular fault. A CONTROL SYSTEM FAULT IS SUSPECTED THE FAULT IS LOGGED IN THE EVENT LOG. THE FAULT IS NOT LOGGED IN THE EVENT LOG COMPRESSOR RELATED I/O FAULT CONTROL PROBLEMS Event correctly indicates a problem. (Refer to the compressor operating manual) Temperature, pressure, load, valve, etc. readings incorrect. (Refer to the Input/Output (I/O) System) Compressor fails to Load, fails to trip, fails to start, etc. STABILITY PROBLEMS mass flow, system pressre, Kw, amps are unstable CONTROLLER PROBLEMS OUI failed, BCM failed, UCM failed, Communications failed. (Refer to Controller Problems Section) Figure 1: Troubleshooting Tree Date of Issue : August

32 Troubleshooting Example The following example will serve as a guide to follow when troubleshooting specific problems. Problem Indication: Oil pressure is low and the CMC OUI is found as shown. Probable Cause Determination: 1. The machine Tripped on Low Oil Pressure, which means the oil pressure, was below the Oil Pressure Trip Value. Figure to the right leads to SYSTEM SETTINGS the assumption that the problem is either compressor or I/O related, because the fault is Event Logged. There are two most likely causes for this event. Actual oil pressure is low. The Auxiliary Oil pump is found to be running and installation of a calibrated pressure sensor shows the actual oil pressure to be above the Oil Pressure Trip Value. Therefore, the mechanical system is operating correctly. The value read by the CMC is incorrect. The oil pressure value displayed on Page 2 of the System Folder shows the oil pressure to be below the test sensor reading and erratic. Additionally, all other analog input readings are normal and not erratic. Therefore, the problem can be isolated to the oil pressure, analog input circuit. The Pressure Monitoring System (PMS) troubleshooting table, found in the following section The Pressure Monitoring System identifies the probable cause for an erratic reading as a loose wire/terminal/connector and specifies Troubleshooting Procedure PMS #1 and 2 as the appropriate procedures. INFO Event Name Time Date 1 Low Oil Press Trip 09:18: Low Oil Press Alarm 09:18: Reset key pressed 09:18: Low Oil Press Trip 09:08: Low Oil Press Alarm 08:58: Load key pressed 08:24: Start key pressed 08:23: Trip Remote 2/3 Not Ready Trouble Procedure Execution: Step 1 of PMS #1 requires disconnecting of the pressure transducer (PT) wires at the terminal strip. When this step is performed, one of the connections is found to be intermittent. When the poor connection is corrected, the erratic reading on the OUI becomes solid. Date of Issue : August

33 Input/Output (I/O) System Temperature Monitoring System (TMS) Description: An RTD (Resistance Temperature Detector-2 Wire) with external transmitter is used by the CMC for temperature monitoring. An RTD resistance (ohmic value) varies with temperature. A transmitter for monitoring by the CMC analog input channel converts the resistance to a 4-20 ma signal. Component specification: Probe: 100 ohm Platinum resistance at 32 F (0 C) with Temperature Coefficient Rating (TCR) of Ohm/Ohm/Deg C Transmitter: The transmitter may be mounted in the RTD connection head fitting or in the control panel enclosure. The transmitter is supplied 24 VDC and outputs 4-20mA over a fixed range of either 0 to 200 F (-17.7 to C), or F (-17.7 to +260 C). Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem Probable Cause Troubleshooting Procedure High OUI readout High resistance connection TMS #4 Transmitter not calibrated TMS #3 RTD failure TMS #2 Transmitter failure TMS #3 Low OUI readout Transmitter failure TMS #3 RTD failure TMS #2 Transmitter not calibrated TMS #3 Erratic OUI readout Loose terminal connection TMS #4 RTD internal wire fault TMS #2 Transmitter failure TMS #3 Incorrect OUI readout Transmitter not calibrated TMS #3 RTD or transmitter failure TMS #2, 3 Any TMS #1, 2, 3, 4 Date of Issue : August

34 XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX PET STAR 4 CMC MANUAL CCN Checking for Power to the Temperature Transmitter TMS #1 1. Disconnect the wires at terminals #1 and #2 on the transmitter and connect a voltmeter to these wires. 2. With control power on, there should be approximately 24 VDC present at the terminals. 3. If approximately 24 VDC is not present, see the section titled Control Power System. BCM J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23 Pin 25 Pin 1 VDC ma VAC ma COM Ω V Ω Temperature transmitter RTD Date of Issue : August

35 XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX PET STAR 4 CMC MANUAL CCN Checking for a Faulty RTD TMS #2 1. Turn control power off. 2. Check ohms versus temperature. Use an Ohmmeter and the following tables to determine if the RTD is faulty. Vary the temperature to the RTD and check the ohms around the normal operating range. VDC ma VAC ma COM Ω VΩ RTD Thermometer 32 DEGF Ice water Date of Issue : August

36 Degrees Fahrenheit versus Ohms value chart for 100 OHM Platinum RTD F Date of Issue : August

37 Degrees Celsius versus Ohms value chart for 100 OHM Platinum RTD C NOTE: This chart converted from Fahrenheit chart using formula C= (( F-32)/1.8) Date of Issue : August

38 Checking the RTD Transmitter TMS #3 1. With control power off, connect a 100-ohm resistor to terminals #3 and #4 of the transmitter. 2. Turn control power on, the OUI reading should be 32 F (0 C) ±5%. 3. If the reading is not within specification, the transmitter may be faulty. BCM J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23 Pin 25 Pin OHM 5% Temperature transmitter Date of Issue : August

39 Checking proper operation of the BCM and wiring TMS #4 1. Ensure control power is off. At the affected RTD transmitter, disconnect the wires at transmitter terminal #1 and #2. Connect a 4-20mA source to these terminals (Observe correct polarity). Power up the control panel and then vary the simulator output. 2. At 12 ma (50%) the OUI should read 1/2 the RTD transmitter range; 100 or 250 F (37.7 or C). The readout should change as the simulator output is varied. 3. If the reading on the OUI is incorrect or does not change, turn control power off and reconnect the transmitter, remove the wires for this transmitter from J1 and move the 4 to 20 ma simulator to the respective terminals at connector J1, (see electrical schematic for connection points). 4. Turn control power on and observe the OUI readout while varying the 4-20mA. If the reading is correct there is an open or short in the wire or terminals connecting the CMC to the RTD transmitter. If reading is not correct the BCM may be faulty. BCM J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels ma SURCE OR 2 WIRE SIMULATOR Pin 25 Pin 1 BATTERY CHECK LOOP ON ma OUT 100% OFF DIAL 2 WIRE 00.0% XXXXXX MODEL CL-XXX 00.0% - 100% Date of Issue : August

40 Pressure Monitoring System (PMS) Description: A Pressure Transducer (PT) is used to convert pressure (psi) to a 4-20 ma signal for monitoring by the CMC. Component specification: 0-50 PSIG ( kpa) range PSIG (1379 kpa) range PSIG ( kpa) range PSIG (6895 kpa) range Power = 24 VDC Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem Probable Cause Troubleshooting Procedure Zero OUI readout Open circuit/cable disconnected PMS #1, 2 Loss of power to transmitter PMS #1 Malfunctioning transmitter PMS #3, 4 Erratic OUI readout Loose wire/terminal/connector PMS #1,2 Incorrect OUI readout Any PMS #1, 2, 3, 4 Date of Issue : August

41 Checking for Power to the Pressure Transmitter PMS #1 1. Ensure control power is off. Disconnect the wires at the suspect PT and connect a voltmeter to these wires. 2. With control power on, there should be approximately 24 VDC present at the terminals. 3. If approximately 24 VDC is not present, see the section titled Control Power System. BCM J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23 Pin 25 Pin 1 XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX VDC ma SPAN VAC ma COM Ω VΩ INGERSOLL RAND Date of Issue : August

42 Checking proper operation of the BCM and wiring PMS #2 1. Ensure control power is off. Disconnect the wires at the suspect PT and connect a 4-20 ma source to the lifted wires (Observe correct polarity). 2. Restore control power and then vary the simulator output. 3. At 12 ma (50%) the OUI should read 1/2 the PT range. The readout should change as the simulator output is varied. 4. If the reading on the OUI is incorrect or does not change, turn control power off and reconnect the transmitter, remove the wires for this transmitter from J1 and move the 4-20 ma simulator to the respective terminals at connector J1, (see electrical schematic for connection points). 5. Turn control power on and observe the OUI readout while varying the 4-20 ma. If the reading is correct there is an open or short in the wire or terminals connecting the CMC to the PT. If the reading is not correct the BCM may be faulty. BCM J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels ma SURCE OR 2 WIRE SIMULATOR Pin 25 Pin 1 BATTERY CHECK LOOP ON ma OUT 100% OFF DIAL 2 WIRE 00.0% XXXXXX MODEL CL-XXX 00.0% - 100% Date of Issue : August

43 Quick check of the PT PMS #3 1. Connect an ohmmeter to the disconnected wires coming from the PT. 2. If there is no continuity either the wiring or the PT is faulty. M XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX VDC ma VAC ma COM Ω VΩ SPAN INGERSOLL RAND Functional PT test PMS #4 1. Remove control power. 2. Remove the PT and connect a regulated air supply to the pressure connection. Power up the CMC and vary the regulated air supply. The OUI should read the pressure being applied. Date of Issue : August

44 Digital Input System (DIS) Description: The digital input devices associated with the CMC are on/off devices that turn on or off the associated CMC digital input. Typical digital device name and type: 1. Starter Feedback 2. E-Stop 3. Remote Communication Enabled 4. Auxiliary Oil Pump in Manual 5. Cooling Water SV in Manual 6. High Motor Bearing Temperature 7. High Motor Winding Temperature 8. Stage 1 Rod Drop Indication Alarm 9. Stage 2 Rod Drop Indication Alarm 10. Stage 3 Rod Drop Indication Alarm 11. Stage 4 Rod Drop Indication Alarm 12. Low Instrument Air Pressure 13. Dryer Fault 14. Dirty Oil Filter Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem Probable Cause Troubleshooting Procedure False alarm or trip Faulty device DIS #1 Faulty wiring DIS #1 Date of Issue : August

45 XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX PET STAR 4 CMC MANUAL CCN Checking proper operation of the digital devices DIS #1 1. Verify approximately 24 VDC is present as described in the section titled Troubleshooting the Power System. 2. If approximately 24 VDC is present, install a multimeter with VDC selected between J4 or J5 pin1 and the input pin (the input pin can be determined from the electrical schematic, or wire number). 3. Ensure the digital device is not in the trip condition, the meter should read 0 VDC. 4. Actuate the switch, the meter should read approximately 24 VDC. J6-RS232 Serial Data Link (Display), Female DB9 BCM J5-Digital (Discrete) Inputs (24 VDC), Channels 9-16 Pin 1 VDC ma J4-Digital (Discrete) Inputs (24 VDC), Channels 1-8 Pin 1 VAC ma COM Ω VΩ Seal Air Switch J3-Analog Outputs (4-20mA) Channels 1-4 Date of Issue : August

46 Control Power System (CPS) Description: The control power system provides 24 VDC to the CMC system for processing logic, displaying data, and monitoring instrumentation. The 24 VDC power supply feeds the Base Control Module (BCM) at connector J10. Over current protection and power distribution are performed as shown below: +24 VDC pins 11 thru 14 Return pins 7 thru 10 J2 Power Supply F1 J1 AC2 pin 3 AC1 pin 1 BCM shown cover removed Fuse 5A/250VAC, normal blo. J12-Digital Output Power 120 VAC (Pin 1) To OUI J2 pin 2 To OUI J2 pin 1 OUI Power To Ground Bar J10-Power Input (24 VDC) F100 F101 F102 F103 J9-Current Transformer (0-5 amp) All BCM Fuses are 5x20mm, GMA 1.5 amp, Fast Blow CPU Power BCM Digital Input Power J4 & J5 - Digital Input Power 24 VDC (pin 1) Analog Input/Output Power LEGEND: Trace Wire J3- Analog Output Power 24 VDC (pins 2 & 8) J1- Analog Input Power 24 VDC (pin 26) Date of Issue : August

47 Power Supply: Input power: VAC, or VAC (auto-selecting input), 2.5A RMS max, Hz. Output power:24 VDC, 4.3 A maximum at 50 C. Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem Probable Cause Troubleshooting Procedure All analog inputs are zero or negative on System Page No AC power CPS #1 No DC power CPS #2 No analog input CPS #5 power OUI displays: INGERSOLL-RAND Centrifugal Compressor Division No CPU power CPS #8 BCM problems CMCS #3 OUI is black No AC power CPS #1 No DC power CPS #2 No OUI power CPS #7 Event Log indicates all digital alarms and trips active No AC power CPS #1 No DC power CPS #2 No digital input power CPS #3 All digital outputs not working No AC power CPS #1 No DC power CPS #2 No digital output CPS #4 power All analog outputs not working No AC power CPS #1 No DC power CPS #2 No analog output power CPS #6 No AC power CPS #1 1. Ensure control power is off. 2. Install a multimeter set for VAC between pins 1 and 3 at connector J1 on the power supply. 3. Restore control power, the meter should read 120 VAC depending upon the rated supply power. The rated supply power can be verified from the electrical schematic. Date of Issue : August

48 No DC power CPS #2 1. Ensure control power is off. 2. Install a multimeter set for VDC between pins and 7-10 at connector J2 on the power supply. 3. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F1 on the power supply, if fuse is good, the power supply may be faulty. 4. Ensure control power is off. 5. Install a multimeter set for VDC between pins 1 and 2 at connector J10 on the BCM. 6. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check the wiring between the power supply and the BCM. No digital input power CPS #3 1. Ensure control power is off. 2. Install a multimeter set for VDC between pin 1 at connector J4 on the BCM and the ground bar. 3. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F103 on the BCM, if F103 is good, check for DC power. No digital output power CPS #4 1. Ensure control power is off. 2. Install a multimeter set for VAC between pin 1 at connector J12 on the BCM and the ground bar. 3. Restore control power, the meter should read 120 VAC. No analog input power CPS #5 1. Ensure control power is off. 2. Install a multimeter set for VDC between pin 26 at connector J1 on the BCM and the ground bar. 3. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F102 on the BCM, if F102 is good, check for DC power. No analog output power CPS #6 1. Ensure control power is off. 2. Install a multimeter set for VDC between pin 2 at connector J3 on the BCM and the ground bar. 3. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F102 on the BCM, if F102 is good, check for DC power. No OUI power CPS #7 1. Ensure control power is off. 2. Install a multimeter set for VDC between pins 1 and 2 at connector J2 on the OUI. 3. Restore control power, the meter should read approximately 24 VCD. If approximately 24VDC is present, check F2 on the OUI. If F2 is good, go to next step. 4. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F101 on the BCM, if F101 is good, check for DC power. Date of Issue : August

49 No CPU power CPS #8 1. Ensure control power is off. 2. Verify approximately 24 VDC is present at J Check F100, if F100 is blown the BCM must be replaced, not the fuse. 4. If F100 is not blown, and the BCM is not functioning, the BCM must be replaced. Controller Problems Description: The CMC System is generally comprised of a Base Control Module (BCM), Operator User Interface (OUI), and Power Supply (PS). There are few user serviceable components within the system; however, a brief understanding of the system will help in overall troubleshooting. All components require 24 VDC and rely on hardware and software to perform correctly, if the problem cannot be isolated to a power problem it is most likely a hardware or software problem, which will require Ingersoll-Rand support to correct. Component Specification: VDC power required Software required Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem Probable Cause Troubleshooting Procedure BCM fault suspected No power CMCS #4 OUI is dim Wrong contrast selected CMCS #1 Backlight failing CMCS #1 OUI is black No power CMCS #2 OUI displays INGERSOLL-RAND Cable disconnected CMCS #3 Centrifugal Compressor Division OUI displays Status XXH Where XX is a specific number Many Refer to Status Codes under System Information Section. MODBUS communications problem No power CMCS #5 Many Refer to the UCM Section. Date of Issue : August

50 BCM Problems BCM is not controlling CMCS #4 1. Check the CPU power as described in the section titled Control Power System. OUI Problems OUI is dim CMCS #1 1. Depress the contrast key to step to the desired brightness. 2. Replace the OUI backlight as described in the section titled Backlight Replacement Procedure. If the backlight does not fix the problem the OUI may be faulty. OUI is black CMCS #2 1. Check for OUI power as described in the section titled Control Power System. If approximately 24 VDC is present, check F2. If F2 is O.K. the OUI may be faulty. OUI displays INGERSOLL-RAND Centrifugal Compressor Division CMCS #3 1. Check the cabling between OUI J1 and BCM J6. 2. The BCM may require programming. 3. Check the BCM CPU power. 4. The BCM may be faulty. UCM Problems All UCM LED s are not lit CMCS #5 1. Check for approximately 24 VDC at pins 1 and 2 at J3 on the UCM. 2. If power is present at J3 the UCM may be faulty. Date of Issue : August

51 Communication Customers may want to communicate to the CMC control systems for remote compressor control and monitoring. This communication capability provides for flexibility in the customer's compressed air operation through remote start and stop, data gathering for preventative maintenance, and incorporation into plant-wide control system. The major avenue for communicating with the CMC is via MODBUS protocol over an RS422/485 hardware link. This requires hardware for the control panel, and a communications device with the appropriate driver software to perform the desired panel functions. The RS422/485 interface can communicate with any serial device that has an RS422 or RS485 port. The customer or his representative must write system software to suit his individual needs for remote control and monitoring. Since the customer writes this interface, the system can be as flexible as the customer desires. Human Machine Interface (HMI) Systems Air System Controller (ASC) and Air System Manager (ASM) are software packages available for compressors with CMC panels. ASC and ASM are graphical integration software specifically developed for air compressor systems. The primary goal of both systems is to maintain stable system pressure, to integrate, monitor and control the compressed air system. ASM is the integration of compressor control software in an off-the-shelf Supervisor Control and Data Acquisition (SCADA) package that is available from various manufacturers. The ASM provides more custom features than does ASC. Both ASC and ASM provide a window into the compressor room by making the raw data from compressors and other equipment available to plant operators and managers in formats that are easy to understand. Implementing the CMC in any HMI system may require additional hardware and/or software upgrade. Direct CMC Communications with RS422/485 For the descriptions that follow, a serial device can be a Personal Computer (PC), Programmable Logic Controller (PLC), Distributed Control System (DCS) or any other device that can transmit, receive and interpret an RS422/485 formatted signal over a hardware link. In the descriptions that follow, the PC and PLC serial devices are not specific to manufacturers or operating systems. There are many ways of interfacing to CMC control systems through an RS422/485 port. Most of the following methodologies are currently available; but please be aware, other possible configurations can exist. All RS422/485 interfaces require custom interface software and custom application software. The interface software allows a specific serial device and operating system to transmit, receive and interpret data from a CMC control system. The application software tells the CMC control system what to do; for example, start compressor when ready, stop compressor after midnight and retrieve the current data and save to a disk file. Currently there are hundreds of different serial devices using different operating systems and languages in the industrial equipment world. Therefore, the practicality of having an interface for many systems is limited. Custom interfaces must be written as required by the hardware and operating system used. Date of Issue : August

52 The capabilities of the hardware and the imagination of the developer only limit the application software. For example, one developer may have two compressors. In this application the developer wants a screen to display the compressor interstage pressure and temperatures for both machines with various other compressor data. A second developer has five compressors. He also wants to display the same data, but this time for all five machines. The only way this is done is through changing the application software (custom modification). The developer may write functions to read and display data, log that data to some magnetic media for storage, change compressor set points, sequence the compressors for efficient operation and network additional devices, such as pumps, dryers, etc., into the system. All of these functions require specially written application software for the intended use. The CMC-MODBUS Interface Introduction The CMC can communicate with other devices over a variety of communications standards. Supported standards, or protocols, include RS-232, IRBUS (Ingersoll-Rand Proprietary), and Modicon s MODBUS. The built-in ports on the CMC s optional Universal Communication Adapters access communications. The CMC-MODBUS Interface defines the message structure that a CMC uses to exist on a MODBUS network. This interface will allow the MODBUS network to gather information and control the compressor. NOTICE Unless specified otherwise, numerical values (such as addresses, codes, or data) are expressed as decimal values in the text of this section. They are expressed as hexadecimal values in the message fields of the examples. Date of Issue : August

53 In order to communicate over other types of networks, a network adapter must be used. The information presented in the following sections does not include MODBUS protocol details like framing messages and calculating checksums. This detailed information can be obtained from Schneider Automation s MODBUS PROTOCOL Manual, Chapters 1 through 6. This can be obtained through the Internet at Serial Modes MODBUS Controllers can be setup to communicate on MODBUS networks using either of two transmission modes: ASCII or RTU. The CMC supports only the RTU mode. The user must specify the serial port communication parameters (baud rate, parity mode, etc.) during configuration of each CMC. The mode and serial parameters must be the same for all devices on a MODBUS network. Master Device Address Function Code Data Address MODBUS Messages A MODBUS network uses a master-slave relationship. The CMC always acts as a slave device. The slave cannot initiate a message, and returns a message (response) only to queries (reads) that are addressed to them individually. For example, a force coil command (write to module) that is broadcast to all MODBUS devices would not get a response. Responses are not returned to broadcast writes from the master. Device Address This address is the physical address of the Universal Communication Module (UCM) for the compressor. This address must be unique in the MODBUS network. The valid range for this address is 01-FF (hexadecimal). NOTE: 00 (hexadecimal) is reserved for broadcast. Configuration of the slave address is available through the Ingersoll-Rand Service Tool and will be provided by a certified Ingersoll-Rand Service Representative. Function Code The listing below shows the function codes that are supported by the CMC. Additional detail about each function is provided in sections that follow. Data CRC Query Response Slave Device Address Function Code Byte Count Data CRC Figure 2: MODBUS Messages Function Code Function Code Function Name (decimal) (hex) 1 01 Read Coil Status 2 02 Read Input Status 3 03 Read Holding Registers 4 04 Read Input Registers 5 05 Force Single Coil 6 06 Preset Single Register 15 0F Force Multiple Coils Preset Multiple Registers Date of Issue : August

54 Data Addresses Addresses that contain the data type and a four-digit number are referred to as absolute (e.g., address 30232, where 3 is the data type for a input register and 0232 or 232 is the address). Software products at the operator or user level use absolute addresses most frequently. The addresses that do not contain the type and are referenced to zero are referred to as relative (e.g., absolute address would be relative address 231, remove the data type 3, holding register, and subtract 1 for referencing to zero). All data addresses in MODBUS messages (typically, behind the scenes at the programming communication level) are referenced to zero; that is, the first occurrence of a data item is addressed as item number zero. Reference Data Type MODBUS Range Absolute Addresses MODBUS Range Relative Addresses CMC Range Absolute Addresses CMC Range Relative Addresses 0x Coils x Discrete Inputs x Input Registers x Holding Registers ) Absolute address for Coil decimal is relatively addressed as coil 007E hex (126 decimal) 2) Input register with absolute address of is relatively addressed as register 0000 in the data address field of the message. The function code field that specifies reading or writing data already specifies an input register operation; therefore, the 3x reference is implicit. 3) Holding register with an absolute address of is relatively addressed as register 006B hex (107 decimal) Single Module Addresses The addresses provided in this document are for compressors with a single Base Control Module. Multiple Module Addresses For those systems that require multiple Base Control Modules, the addresses for the first module will be as provided within this document. The addresses for the second module will be provided as an engineering submittal. Data For both queries and responses, the data is in sixteen bit (two bytes, one word) chunks. For each two byte word, the left most byte is the most significant. For each byte, the left most bit is the most significant. This portion of the message changes with each function code. See the detail that follows for each function for the specifics of this message component. Byte Count The number of bytes contained in the data portion of the message. This is used on both queries (reads) and responses. Cyclical Redundancy Check (CRC) This portion of the message is used to prevent incorrect data from being used in the Master or Slave because of communication errors. Date of Issue : August

55 Function Details Function 01 - Read Coil Status This function reads the state of one or more coils (MODBUS 0x references) in the slave (CMC Base Control Module). For the CMC, these coils represent the Discrete (Digital) Outputs, compressor operating state (see the Operator User Interface Status Bar for definition), any compressor Trip condition and any compressor Alarm condition. If the function returns a 1, the discrete output is on. If the function returns a 0, the discrete output is off. Broadcast is not supported. Refer to the table on the next page for MODBUS Absolute Addresses for each coil supported by the CMC-MODBUS Interface. Absolute Address (decimal) Relative Address (hex) Coil Name - Read Only* Absolute Address (decimal) Relative Address (hex) Coil Name - Read Only* BA Digital Output, Channel 1 (J15-P7,8) CA Compressor State - Waiting BB Digital Output, Channel 2 (J15-P5,6) CB Compressor State - Coasting BC Digital Output, Channel 3 (J15-P3,4) CC Compressor State - Starting BD Digital Output, Channel 4 (J15-P1,2) CD Compressor State - Not Ready BE Digital Output, Channel 5 (J14-P7,8) CE Compressor State - Ready BF Digital Output, Channel 6 (J14-P5,6) D0 Compressor State No Unload C0 Digital Output, Channel 7 (J14-P3,4) D2 Compressor State Unloaded C1 Digital Output, Channel 8 (J14-P1,2) D3 Compressor State - Min load C2 Digital Output, Channel 9 (J13-P7,8) D4 Compressor State - Max load C3 Digital Output, Channel 10 (J13-P5,6) D9 Any Compressor Trip C4 Digital Output, Channel 11 (J13-P3,4) DA Any Compressor Alarm C5 Digital Output, Channel 12 (J13-P1,2) C6 Digital Output, Channel 13 (J12-P7,8) C7 Digital Output, Channel 14 (J12-P5,6) C8 Digital Output, Channel 15 (J12-P3,4) C9 Digital Output, Channel 16 (J12-P1,2) NOTE: (J15-P7,8) is interpreted as Connector J15, Pins 7 and 8 on the Base Control Module. * IMPORTANT: These coils are defined as read only. If you decide to write to these coils, unexpected results could occur. Example: Reading a Single Coil After reviewing the Electrical Schematic for your compressor, you determine that the digital output for the common Alarm Indication contact is located on J12-P7,8 (Channel 13). From the table above, the Absolute Address is decimal (Relative Address is hexadecimal 00C6) for the output in question. Therefore, to read the state of the Common Alarm Indication contact output the following command is issued (the following data are presented in hexadecimal format): Number of Device Function Address Coils CRC Address Code Hi Lo Hi Lo Lo Hi C D F7 The response from this command is: Device Function Byte CRC Address Code Count Data Lo Hi The data (01) means that the discrete output is on, or there is a common Alarm. Date of Issue : August

56 Example: Reading Multiple Coils To read all sixteen digital (discrete) outputs, the following command is sent: Number of Device Function Address Coils CRC Address Code Hi Lo Hi Lo Lo Hi BA C 23 Where relative address 00-BA is for digital (discrete) output for Channel 1. The response from this command is: Device Function Byte CRC Address Code Count Data Lo Hi BA F0 To determine the state of each output, review the Electrical Schematic for your compressor. For this example, you determine that the digital output for the Common Alarm Indication contact is located on J12-P7,8 (Channel 13) and the digital output for the Trouble Indication Light is J15-P3,4 (Channel 3). The first hexadecimal data byte 04 ( binary), represents the states of the first eight digital (discrete) outputs (8-1). Therefore, for this example 04 means that Channels 8, 7, 6, 5, 4, 2 and 1 are off and Channel 3 (compressor trouble Indication Light is ON ) is on. For the next eight channels (16-9) the hexadecimal data byte 10 ( binary) means that Channels 16, 15, 14, 12, 11, 10 and 9 are off and Channel 13 ( Common Alarm contact is there ) is on. The following table graphically depicts this example: Response Byte Address C1 C0 BF BE BD BC BB BA Response Byte Address C9 C8 C7 C6 C5 C4 C3 C2 A bit response of 1 means that the output is on and a response of 0 mean that the output is off. Function 02 - Read Input Status This function reads the state of one or more discrete inputs (MODBUS 1x references) in the slave (CMC Base Control Module). For the CMC, these inputs represent the Discrete (Digital) Inputs. If the function returns a 1, the input is on. If the function returns a 0, the input is off. Broadcast is not supported. Refer to the table on the next page for MODBUS Absolute Addresses for each discrete input supported by the CMC-MODBUS Interface. Date of Issue : August

57 Example: Read Single Discrete Input After reviewing the Electrical Schematic for your compressor, you determine that the digital input for emergency stop push button is located on J4-P8 (Channel 7). From the table above, the Absolute Address is decimal (Relative Address is hexadecimal 00B0) for the input in question. Therefore, to read the state of the emergency stop push button the following command is issued (the following data are presented in hexadecimal format): The response from this command is: Absolute Address Relative Address Input Name - Read Only* (decimal) (hex) AA Digital Input, Channel 1 (J4-P2) AB Digital Input, Channel 2 (J4-P3) AC Digital Input, Channel 3 (J4-P4) AD Digital Input, Channel 4 (J4-P5) AE Digital Input, Channel 5 (J4-P6) AF Digital Input, Channel 6 (J4-P7) B0 Digital Input, Channel 7 (J4-P8) B1 Digital Input, Channel 8 (J4-P9) B2 Digital Input, Channel 9 (J5-P2) B3 Digital Input, Channel 10 (J5-P3) B4 Digital Input, Channel 11 (J5-P4) B5 Digital Input, Channel 12 (J5-P5) B6 Digital Input, Channel 13 (J5-P6) B7 Digital Input, Channel 14 (J5-P7) B8 Digital Input, Channel 15 (J5-P8) B9 Digital Input, Channel 16 (J5-P9) NOTE: (J4-P2) is interpreted as Connector J4, Pin 2 on the Base Control Module. * IMPORTANT: These Digital Inputs are defined as read only. If you decide to write to these Inputs, unexpected results could occur. Number of Device Function Address Digital Inputs CRC Address Code Hi Lo Hi Lo Lo Hi B B Device Function Byte CRC Address Code Count Data Lo Hi The data (01) means that the input is on, or the emergency stop push button is pressed. Example: Read Multiple Discrete Inputs The method for reading multiple Discrete Inputs is the same as reading multiple coils. See the example for Reading Multiple Coils. Function 03 - Read Holding Registers Reads the binary content of holding registers (MODBUS 4x references) in the slave (CMC Base Control Module). For the CMC, these holding registers contain the Analog Output values and Analog Alarm and Trip Setpoint values for all CMC inputs and outputs. Broadcast is not supported. The CMC is primarily a 32-bit floating-point microprocessor controller. And, since MODBUS is designed to be a 16-bit system, the CMC supports two methods for determining the value for each holding register (This also applies to Input Registers.) Date of Issue : August

58 NOTICE Since MODBUS is a 16-bit system, the programmer must get two 16-bit numbers and combine them into one 32-bit floating-point number. The first method uses two 16-bit integers to represent the integer and fraction part of the value. The second method uses one 32-bit IEEE floating point number. (NOTE: For those who would like to only get the 16-bit integer value, this will work well for most inputs; however, the CMC has some inputs, like vibration, that are typically less than one. Since the CMC has programmable analog and discrete inputs and outputs, the programmer must use the electrical schematic supplied with the contract to determine which function name and units of measure are associated with each input and output. Refer to the table below for MODBUS Absolute Addresses for each Holding Register supported by the CMC-MODBUS Interface. Date of Issue : August

59 Holding Register Name - Read/Write Signed 16 Bit Exponent Absolute Address (Decimal) Relative Address (hex) Unsigned 16 Bit Fraction Absolute Address (Decimal) Relative Address (hex) Signed IEEE 32-Bit Float Absolute Address (Decimal) Relative Address (hex) Analog Output, Channel 1 (J3-P1,3) B-EC Analog Output, Channel 2 (J3-P4,6) B-EE Analog Output, Channel 3 (J3-P7,9) B-F0 Analog Output, Channel 4 (J3-P10,12) A B B-F2 Analog Input, Channel 1 (J2-P1,3) - High Trip Set point C D B-F4 Analog Input, Channel 1 (J2-P1,3) - High Alarm Set point E F B-F6 Analog Input, Channel 1 (J2-P1,3) - Low Alarm Setpoint B-F8 Analog Input, Channel 1 (J2-P1,3) - Low Trip Setpoint B-FA Analog Input, Channel 2 (J2-P5,7) - High Trip Setpoint B-FC Analog Input, Channel 2 (J2-P5,7) - High Alarm Setpoint B-FE Analog Input, Channel 2 (J2-P5,7) - Low Alarm Setpoint C-00 Analog Input, Channel 2 (J2-P5,7) - Low Trip Setpoint A B C-02 Analog Input, Channel 3 (J1-P1) - High Trip Setpoint C D C-04 Analog Input, Channel 3 (J1-P1) - High Alarm Setpoint E F C-06 Analog Input, Channel 3 (J1-P1) - Low Alarm Setpoint C-08 Analog Input, Channel 3 (J1-P1) - Low Trip Setpoint C-0A Analog Input, Channel 4 (J1-P4) - High Trip Setpoint C-0C Analog Input, Channel 4 (J1-P4) - High Alarm Setpoint C-0E Analog Input, Channel 4 (J1-P4) - Low Alarm Setpoint C-10 Analog Input, Channel 4 (J1-P4) - Low Trip Setpoint A B C-12 Analog Input, Channel 5 (J1-P5) - High Trip Setpoint C D C-14 Analog Input, Channel 5 (J1-P5) - High Alarm Setpoint E F C-16 Analog Input, Channel 5 (J1-P5) - Low Alarm Setpoint C-18 Analog Input, Channel 5 (J1-P5) - Low Trip Setpoint C-1A Analog Input, Channel 6 (J1-P8) - High Trip Setpoint C-1C Analog Input, Channel 6 (J1-P8) - High Alarm Setpoint C-1E Analog Input, Channel 6 (J1-P8) - Low Alarm Setpoint C-20 Analog Input, Channel 6 (J1-P8) - Low Trip Setpoint A B C-22 Analog Input, Channel 7 (J1-P9) - High Trip Setpoint C D C-24 Analog Input, Channel 7 (J1-P9) - High Alarm Setpoint E F C-26 Analog Input, Channel 7 (J1-P9) - Low Alarm Setpoint C-28 Analog Input, Channel 7 (J1-P9) - Low Trip Setpoint C-2A Analog Input, Channel 8 (J1-P12) - High Trip Setpoint C-2C Analog Input, Channel 8 (J1-P12) - High Alarm Setpoint C-2E Analog Input, Channel 8 (J1-P12) - Low Alarm Setpoint C-30 Analog Input, Channel 8 (J1-P12) - Low Trip Setpoint A B C-32 Analog Input, Channel 9 (J1-P13) - High Trip Setpoint C D C-34 Analog Input, Channel 9 (J1-P13) - High Alarm Setpoint E F C-36 Analog Input, Channel 9 (J1-P13) - Low Alarm Setpoint C-38 Analog Input, Channel 9 (J1-P13) - Low Trip Setpoint C-3A Analog Input, Channel 10 (J1-P16) - High Trip Setpoint C-3C Analog Input, Channel 10 (J1-P16) - High Alarm Setpoint C-3E Analog Input, Channel 10 (J1-P16) - Low Alarm Setpoint C-40 Analog Input, Channel 10 (J1-P16) - Low Trip Setpoint A B C-42 Analog Input, Channel 11 (J1-P17) - High Trip Setpoint C D C-44 Analog Input, Channel 11 (J1-P17) - High Alarm Setpoint E F C-46 Analog Input, Channel 11 (J1-P17) - Low Alarm Setpoint C-48 Analog Input, Channel 11 (J1-P17) - Low Trip Setpoint C-4A Analog Input, Channel 12 (J1-P20) - High Trip Setpoint C-4C Analog Input, Channel 12 (J1-P20) - High Alarm Setpoint C-4E Analog Input, Channel 12 (J1-P20) - Low Alarm Setpoint C-50 Analog Input, Channel 12 (J1-P20) - Low Trip Setpoint A B C-52 Analog Input, Channel 13 (J1-P21) - High Trip Setpoint C D C-54 Analog Input, Channel 13 (J1-P21) - High Alarm Setpoint E F C-56 Analog Input, Channel 13 (J1-P21) - Low Alarm Setpoint A A C-58 Analog Input, Channel 13 (J1-P21) - Low Trip Setpoint A A C-5A Date of Issue : August

60 Holding Register Name - Read/Write Signed 16 Bit Exponent Absolute Address (Decimal) Relative Address (hex) Unsigned 16 Bit Fraction Absolute Address (Decimal) Relative Address (hex) Signed IEEE 32-Bit Float Absolute Address (Decimal) Relative Address (hex) Analog Input, Channel 14 (J1-P24) - High Trip Setpoint A A C-5C Analog Input, Channel 14 (J1-P24) - High Alarm Setpoint A A C-5E Analog Input, Channel 14 (J1-P24) - Low Alarm Setpoint A A C-60 Analog Input, Channel 14 (J1-P24) - Low Trip Setpoint AA AB C-62 Analog Input, Channel 15 (J1-P25) - High Trip Setpoint AC AD C-64 Analog Input, Channel 15 (J1-P25) - High Alarm Setpoint AE AF C-66 Analog Input, Channel 15 (J1-P25) - Low Alarm Setpoint B B C-68 Analog Input, Channel 15 (J1-P25) - Low Trip Setpoint B B C-6A Analog Input, Channel 16 (J1-P28) - High Trip Setpoint B B C-6C Analog Input, Channel 16 (J1-P28) - High Alarm Setpoint B B C-6E Analog Input, Channel 16 (J1-P28) - Low Alarm Setpoint B B C-70 Analog Input, Channel 16 (J1-P28) - Low Trip Setpoint BA BB C-72 Analog Input, Channel 17 (J1-P29) - High Trip Setpoint BC BD C-74 Analog Input, Channel 17 (J1-P29) - High Alarm Setpoint BE BF C-76 Analog Input, Channel 17 (J1-P29) - Low Alarm Setpoint C C C-78 Analog Input, Channel 17 (J1-P29) - Low Trip Setpoint C C C-7A Analog Input, Channel 18 (J1-P32) - High Trip Setpoint C C C-7C Analog Input, Channel 18 (J1-P32) - High Alarm Setpoint C C C-7E Analog Input, Channel 18 (J1-P32) - Low Alarm Setpoint C C C-80 Analog Input, Channel 18 (J1-P32) - Low Trip Setpoint CA CB C-82 Analog Input, Channel 19 (J1-P33) - High Trip Setpoint CC CD C-84 Analog Input, Channel 19 (J1-P33) - High Alarm Setpoint CE CF C-86 Analog Input, Channel 19 (J1-P33) - Low Alarm Setpoint D D C-88 Analog Input, Channel 19 (J1-P33) - Low Trip Setpoint D D C-8A Analog Input, Channel 20 (J1-P36) - High Trip Setpoint D D C-8C Analog Input, Channel 20 (J1-P36) - High Alarm Setpoint D D C-8E Analog Input, Channel 20 (J1-P36) - Low Alarm Setpoint D D C-90 Analog Input, Channel 20 (J1-P36) - Low Trip Setpoint DA DB C-92 Analog Input, Channel 21 (J1-P37) - High Trip Setpoint DC DD C-94 Analog Input, Channel 21 (J1-P37) - High Alarm Setpoint DE DF C-96 Analog Input, Channel 21 (J1-P37) - Low Alarm Setpoint E E C-98 Analog Input, Channel 21 (J1-P37) - Low Trip Setpoint E E C-9A Analog Input, Channel 22 (J1-P40) - High Trip Setpoint E E C-9C Analog Input, Channel 22 (J1-P40) - High Alarm Setpoint E E C-9E Analog Input, Channel 22 (J1-P40) - Low Alarm Setpoint E E C-A0 Analog Input, Channel 22 (J1-P40) - Low Trip Setpoint EA EB C-A2 Analog Input, Channel 23 (J1-P41) - High Trip Setpoint EC ED C-A4 Analog Input, Channel 23 (J1-P41) - High Alarm Setpoint EE EF C-A6 Analog Input, Channel 23 (J1-P41) - Low Alarm Setpoint F F C-A8 Analog Input, Channel 23 (J1-P41) - Low Trip Setpoint F F C-AA Motor Current A B C-C2 Start Timer C D C-D4 CT Ratio E F C-D6 Unload Delay Timer,Seconds C-DE Coast Timer,Seconds C-EA Compressor Control Mode D-0A Load Pressure Set Point,psig F F D-AE Set Pressure Set point,psig F F D-B0 Water Solenoid valve Timer,Seconds FA FB D-B2 Auxilary Oil Pump Recovery Timer,Seconds FC FD D-B4 Power On Hours C-E0 Running Hours A B C-E2 Loaded Hours C D C-E4 Number of Starts E F C-E6 Phone Number Digit F F AA Phone Number Digit F F AC Phone Number Digit F F AE Phone Number Digit F F B0 Phone Number Digit FA FB B2 Phone Number Digit FC FD B4 Phone Number Digit FE FF B6 Date of Issue : August

61 Phone Number Digit B8 Phone Number Digit BA Phone Number Digit BC Phone Number Digit BE Phone Number Digit C0 Phone Number Digit A B C2 Phone Number Digit C D C4 Phone Number Digit E F C6 Phone Number Digit C8 Phone Number Digit CA Phone Number Digit CC Phone Number Digit CE Phone Number Digit D0 Phone Number Digit A B D2 Phone Number Digit C D D4 Phone Number Digit E F D6 Phone Number Digit D8 Example: See example for Function 04. Function 04 - Read Input Registers Reads the binary content of input registers (MODBUS 3x references) in the slave (CMC Base Control Module). For the CMC, these input registers refer to the Analog Input values. Broadcast is not supported. The CMC is primarily a 32-bit floating-point microprocessor controller. And, since MODBUS is designed to be a 16-bit system, the CMC supports two methods for determining the value for each holding register. (This also applies to Input Registers.) The first method uses two 16-bit integers to represent the integer and fraction part of the value. The second method uses one 32-bit IEEE floating point number. NOTICE Since MODBUS is a 16-bit system, the programmer must get two 16-bit numbers and combine them into one 32-bit floating-point number. For those who would like to only get the 16-bit integer value, this will work well for most inputs; however, the CMC has some inputs, like vibration, that are typically less than one. Date of Issue : August

62 Input Register Name - Read Only* Signed 16-Bit Integer Absolute Address (Decimal) Relative Address (hex) Unsigned 16-Bit Fraction Absolute Address (Decimal) Relative Address (hex) Signed IEEE 32-Bit Float Absolute Address (Decimal) Relative Address (hex) Analog Input, Channel 1 (J2-P1,3) B-BA Analog Input, Channel 2 (J2-P5,7) B-BC Analog Input, Channel 3 (J1-P1) B-BE Analog Input, Channel 4 (J1-P4) B-C0 Analog Input, Channel 5 (J1-P5) A B B-C2 Analog Input, Channel 6 (J1-P8) C D B-C4 Analog Input, Channel 7 (J1-P9) E F B-C6 Analog Input, Channel 8 (J1-P12) B-C8 Analog Input, Channel 9 (J1-P13) B-CA Analog Input, Channel 10 (J1-P16) B-CC Analog Input, Channel 11 (J1-P17) B-CE Analog Input, Channel 12 (J1-P20) B-D0 Analog Input, Channel 13 (J1-P21) A B B-D2 Analog Input, Channel 14 (J1-P24) C D B-D4 Analog Input, Channel 15 (J1-P25) E F B-D6 Analog Input, Channel 16 (J1-P28) B-D8 Analog Input, Channel 17 (J1-P29) B-DA Analog Input, Channel 18 (J1-P32) B-DC Analog Input, Channel 19 (J1-P33) B-DE Analog Input, Channel 20 (J1-P36) B-E0 Analog Input, Channel 21 (J1-P37) A B B-E2 Analog Input, Channel 22 (J1-P40) C D B-E4 Analog Input, Channel 23 (J1-P41) E F B-E6 CT Input (J9-P1,2) B-E8 NOTE: (J1-P1) is interpreted as Connector J1, Pin 1 on the Base Control Module. * IMPORTANT: These Input Registers are defined as read only. If you decide to write to these Input Registers, unexpected results could occur. Example: Read Single Channel 16-Bit Integer and Fraction After reviewing the Electrical Schematic for your compressor, you determine that the analog input for Stage 2 Inlet Temperature is located on J1-P1 (Channel 3). From the table above, the Absolute Address is decimal (Relative Address is hexadecimal 0006) for the input in question. Therefore, to read the 16 Bit Integer and 16 Bit Fraction for Stage 2 Inlet Temperature the following command is issued (the following data are presented in hexadecimal format): Number of Device Function Address Registers CRC Address Code Hi Lo Hi Lo Lo Hi CA The response from this command is: Data Device Function Byte Reg-1 Reg-2 CRC Address Code Count Hi Lo Hi Lo Lo Hi E 37 5F Register 1 is the Integer portion of the Stage 2 Inlet Temp or (0064h, 100 decimal). Register 2 is the Fraction portion of the Stage 2 Inlet Temp or (134Eh, 4942 decimal). Each fraction has a range between 0 and So the Stage 2 Inlet Temp, expressed as a floating point number is Deg F. Example: Read Single Channel IEEE 32-Bit Floating Point Number To continue with the example, when you decide to get the System Pressure as an IEEE 32 Bit floating point number you must issue the following command: Date of Issue : August

63 Number of Device Function Address Registers CRC Address Code Hi Lo Hi Lo Lo Hi B BE CB The response from this command is: Data Device Function Byte Reg-1 Reg-2 CRC Address Code Count Hi Lo Hi Lo Lo Hi DC D4 C6 F1 54 So the System Pressure, expressed as a floating point number is psi. IEEE floating-point numbers are represented in 32 bits as shown below exponent mantissa sign Convert hexadecimal registers 1 and 2 (Reg-1, Reg-2) into decimal values... Register Byte Symbol Hex Decimal 1 Hi R1HB Lo R1LB DC Hi R2HB D Lo R2LB C6 198 Determine the sign (positive = 0 or negative = 1)... Sign = (R1HB And 128) / 128, where And is defined as a bit-wise And Sign = (66 And 128) / 128 = 0 Determine the exponent... Exponent = ((R1HB And 127) 2) + INT(R1LB / 128), where INT is defined as INTEGER Exponent = ((66 And 127) 2) + INT(220/128) = 133 Determine the mantissa... Mantissa = ((((R1LB And 127) 256) + R2HB) 256) + R2LB Mantissa = ((((220 And 127) 256) + 212) 256) = Putting the 32 bit IEEE value together... Value = (-1 sign ) (2 (exponent - 127) ) ((Mantissa 2-23 ) + 1) Value = (-1 0 ) (2 ( ) ) (( ) + 1) = NOTICE When Sign = Exponent = Mantissa = 0, Value = 0. This is a special case for the above equation. Date of Issue : August

64 Example: Read Multiple Channels The procedure for reading multiple channels is the same as reading a single channel with the exception of requesting more data. NOTE: You must read a contiguous group of registers (channels) for a single command. Function 05 - Force Single Coil Forces a single coil (MODBUS 0x references) to either ON or OFF. When broadcast, the function forces the same coil reference in all attached slaves. Refer to the table below for MODBUS Absolute Addresses for each coil supported by the CMC-MODBUS Interface. NOTICE The Force Single Coil command will override the CMC s current state. The forced state will remain valid until the CMC next solves the coil. The coil will remain forced if it is not programmed in the CMC logic. CAUTION For all of the following Remote Coils, the compressor s REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch must be in the ENABLED position for these commands to execute. When DISABLED, the CMC ignores (there is no exception response) these coils being forced ON or OFF. Absolute Address (decimal) Relative Address (hex) Coil Name - Write Only DC Remote Horn Silence (Acknowledge) DD Remote Reset DE Remote Load DF Remote Unload E0 Remote Start E1 Remote Stop Example: Forcing a Coil For all MODBUS devices, a value of FF 00 hex requests the coil to be ON. A value of requests it to be OFF. All other values are illegal and will not affect the coil. NOTE: For the CMC, forcing the above listed coils OFF is not meaningful because the default state of each of the above coils is OFF. When using these commands, they should be sent once (momentary) and the CMC will execute the commands. To remotely reset the compressor, the following command is issued: Forced Device Function Address Data CRC Address Code Hi Lo Hi Lo Lo Hi DD FF 00 1C 00 Date of Issue : August

65 The response from this command is identical to the command sent: Number of Device Function Address Registers CRC Address Code Hi Lo Hi Lo Lo Hi DD FF 00 1C 00 Function 06 - Preset Single Register Presets a value into a single holding register (MODBUS 4x reference). When broadcast, the function presets the same register reference in all attached slaves. Refer to the table for the Holding Register list for the MODBUS Absolute Addresses supported by the CMC-MODBUS Interface. NOTICE The Preset Single Register command will override the CMC s current state. The preset value will remain valid in the register until the CMC logic next solves the register contents. The register's value will remain if it is not programmed in the controller's logic. CAUTION This function can only set a single 16-bit holding register. Since the CMC operates with 32-bit values, you must use Function 16 (10 Hex) - Preset Multiple Registers for setting the 32-bit IEEE register values. Also, you may not set the 16-bit fraction without its 16-bit integer. Therefore, you must use the Preset Multiple Registers function to send this 32-bit pair. See the examples that follow for Function 16. Example: Presetting a Single Register (16-bit) Integer To change the integer value for the User Pressure Setpoint (absolute address 40269, relative address 01-0C) to 100 (00-64 hex) psi, send the following command... Register Device Function Address Value CRC Address Code Hi Lo Hi Lo Lo Hi C DE The response from this command is identical to the command sent: Register Device Function Address Value CRC Address Code Hi Lo Hi Lo Lo Hi C DE Function 15 (0F Hex) - Force Multiple Coils Forces each coil (MODBUS 0x reference) in a series of contiguous coils to either ON or OFF. When broadcast, the function forces the same coil references in all attached slaves (CMC Base Control Modules). Refer to the table for the Coil list for the MODBUS Absolute Addresses supported by the CMC-MODBUS Interface. Date of Issue : August

66 NOTICE The Force Multiple Coils command will override the CMC s current state. The forced state will remain valid until the CMC next solves the coil. The coil will remain forced if it is not programmed in the controller's logic. CAUTION The position of the REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is NOT considered when forcing coils or writing registers to the CMC. Reads and Writes are always enabled. Repeatedly writing a value to a register or forcing a coil without regard to the position of the switch can effectively disable a local write. Please use caution when writing registers or forcing coils. The REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is typically located on the front door of the Compressor s Control Panel. Example: Forcing Multiple Coils To force a reset (absolute address 00222, relative address DD) and start (absolute address 00225, relative address E0) of the compressor the following command is sent... Device Function Address Number of Coils Number of Data Coil Data CRC Address Code Hi Lo Hi Lo Bytes Lo Lo Hi 01 0F 00 DD The number of contiguous coils is four (00225, 00224, and 00222). The number of data bytes is one because we can set up to eight coils in a single byte. The coil data is nine because we want to set the first bit and fourth bit in the byte ( , the bytes are numbered right to left). All bits not used are padded with zero. The response from this command is similar to the command sent except that the number of data bytes and the coil data themselves are not echoed: Number of Device Function Address Coils CRC Address Code Hi Lo Hi Lo Lo Hi 01 0F 00 DD C4 32 Function 16 (10 Hex) - Preset Multiple Registers Presets values into a sequence of contiguous holding registers (MODBUS 4x references). When broadcast, the function presets the same register references in all attached slaves (CMC Base Control Modules). Refer to the table for the Input Register list for the MODBUS Absolute Addresses supported by the CMC-MODBUS Interface. NOTICE The Preset Multiple Registers command will override the CMC s current state. The forced state will remain valid until the CMC next solves the register. The register will remain forced if it is not programmed in the controller's logic. Date of Issue : August

67 Example: Presetting Holding Registers for 32-bit Values The difficulty in setting 32-bit values is determining the four data bytes for the number you want to send. The process required is... 1) Determine the sign (positive = 0 or negative = 1). This is the first bit. 2) Divide the decimal value by 2 until the result is less than 2, but greater than 1. Count the number of iterations required. Add 127 to the number of iterations. This result is the exponent. Convert this result to binary. These are the next eight bits. 3)From the result obtained from step 2, subtract 1. Then, multiply this result by 2. If the result is less than 1, then the value of the first mantissa bit is 0. Otherwise, the mantissa bit is 1. If the result is greater than or equal to 1, then subtract 1 from the result and proceed with step 3 until the result is 0 or you have gone through this process 23 times. 1)Combine all 32 bits from the steps above and convert this value to hexadecimal. These 32 bits are the 4 hexadecimal data bytes needed for the command. As an example, we will start with the decimal value of Since this is a positive number, the first bit is Determine the exponent bits by... It took us six iterations to get the result to a number that is less than two and greater than or equal to one. Now, we must add 127 for an exponent of 133. Converting this to binary, the next eight bits are represented as Determine the mantissa bits by From the table at right, represent the next 23 bits. 4. Combining the bits in sign, exponent and then mantissa order This converts to 42-D2-CC-CC in hexadecimal. To change the holding registers for set pressure set point (for 32 bit IEEE floating point numbers the absolute address is 43505, relative address 0D-B0) to 105.4, issue the following command... Iteration Decimal Result / 2 = / 2 = / 2 = / 2 = / 2 = / 2 = Iteration Decimal Operatio Result Bit n * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = * 2 = Device Function Address Number of Registers Number of Data Data Bytes for Register #1 Data Bytes for Register #2 CRC Address Code Hi Lo Hi Lo Bytes Hi Lo Hi Lo Lo Hi D B D2 CC CC 4A 18 The response from this command is similar to the command sent except that the number of data bytes and the data bytes themselves are not echoed: Number of Device Function Address Registers CRC Address Code Hi Lo Hi Lo Lo Hi D B Date of Issue : August

68 NOTICE Sending 32 bit values are typically not necessary. Sending the data as a 16 bit integer only or a 16 bit integer and 16 bit fraction will satisfy most requirements. Some systems have 32 bit capability built directly into their products. We have provided this feature for those systems. Example: Presetting a 16-bit Integer and 16-bit Fraction Holding Register Change the integer and fraction value for the set pressure set point (absolute address 40503, relative address 01-F6) to psi. The integer portion of the number 110 (00-6E hex) is placed at address and the fraction 0.5 is converted to 5000 (13-88 hex) and is placed at address (or the second data byte). To change the register, issue the following command... Device Function Address Number of Registers Number of Data Data Bytes for Register #1 Data Bytes for Register #2 CRC Address Code Hi Lo Hi Lo Bytes Hi Lo Hi Lo Lo Hi F E E1 The response from this command is similar to the command sent except that the number of data bytes and the data bytes themselves are not echoed: Number of Device Function Address Registers CRC Address Code Hi Lo Hi Lo Lo Hi F Exception Responses Except for broadcast messages, when a master device sends a query to a slave device it expects a normal response, in all other cases a time out or exception response is returned. The four possible responses to a the master's query are: If the slave device receives the query without a communication error, and can handle the query normally, it returns a normal response. If the slave does not receive the query due to a communication error, no response is returned. The master program will eventually process a time-out condition for the query. If the slave receives the query, but detects a communication error (parity, or CRC), no response is returned. The master program will eventually process a time-out condition for the query. If the slave receives the query without a communication error, but cannot handle it (for example, if the request is to read a nonexistent coil or register), the slave will return an exception response informing the master of the nature of the error. The exception response message has two fields that differentiate it from a normal response: Date of Issue : August

69 Function Code Field For a normal response, the UCM echoes the function code of the original query in the function code field of the response. All function codes have their most significant bits set to zero; therefore, the values are always below 80 hexadecimal. When an exception response occurs, the UCM sets the most significant bit of the function code to 1. This makes the function code value in an exception response exactly 80 hexadecimal higher than the value would be for a normal response. Most Significant Bit Least Significant Bit With the function code's most significant bit set, the application program can recognize an exception response and can examine the data field for the exception code. Data Field For a normal response, the UCM will return information in the data field (depending upon the query message sent). For an exception response, the UCM returns an exception code in the data field. This defines the UCM s condition that caused the exception. Exception Codes Supported by the CMC Micro controller Code Name Meaning 01 Illegal Function The function code received in the query is not an allowable action for the slave. This exception code happens when: (1) the function code is other than 1, 2, 3, 4, 5, 6, 15 or 16 (2) a message has the incorrect number of bytes for the function specified 02 Illegal Data Address The data address received in the query is not an allowable address for the slave. This exception code happens when: (1) the address is not programmed into the Base Control Module (BCM) (2) the address is outside of the ranges (a) for coils (b) for discrete inputs (c) for integer and fractional analog inputs (d) for floating point analog inputs (e) for integer and fractional input registers (f) for floating point analog input registers 03 Illegal Data Value A value contained in the query data field is not an allowable value for the slave. This exception code happens when: (1) the number of coils, discrete inputs, registers or analog inputs is equal to zero (2) request for more than the maximum number of parameters (3) the force single coil command, Function 05, is issued and the value is other than FF00 or 0000 (4) the force multiple coil command, Function 15, is issued and the number of bytes does not equal the number of bits to set (5) the preset single register command, Function 6, or preset multiple registers commands, Function 16, is issued and the starting address is not even, or the number of registers specified does not correspond to the number of bytes in the message, or the integer part of the number is outside the range to , or the fractional part of the number is outside of the range , or the value is not a valid 32 bit IEEE floating point number 04 Slave Device Failure An unrecoverable error occurred while the slave was attempting to perform the requested action. This exception code happens when: (1) no response from the Base Control Module (BCM) since 800 milliseconds from the time the message was sent BCM not wired properly, BCM hardware problem or BCM Module ID not equal to one (2) when there is an unexpected response from the BCM this is the default exception response Maximum Query / Response Parameters The listing below shows the maximum amount of data that the CMC Micro controller can return in a single slave response from a valid MODBUS command. Date of Issue : August

70 Function Maximum Dec Hex Description Parameters Read Coil Status 512 coils Read Input Status 512 inputs Read Holding Registers 64 registers Read Input Registers 64 registers Force Single Coil 1 coil Preset Single Register 1 register 15 0F Force Multiple Coils 512 coils Preset Multiple Registers 64 registers CMC Data The CMC Micro controller supports several data types. They are coil, integer, fraction and floating point. Coil - 1 bit, 1 means true or Active, 0 means False or Not Active. Integer - 16 bit signed integer, to Fraction - 16 bit unsigned integer, , represents the decimal (fractional) part of the number (1 represents , 10 represents , 100 represents and 1000 represents ). Floating Point - 32-bit IEEE number (requires reading two registers to get full number). For example if the Stage 2 Inlet temperature input is located on Channel 3 (address 30007) and the value of the temp is then: Address contains 100 Address contains 5000 Address contains the high 16 bits of the IEEE value for Address contains the low 16 bits of IEEE value for Additionally, the type of data in a location determines the commands that can be used to access the data. For the previous example of Stage 2 Inlet temperature addresses 00007, 03007, 10007, 13007, and return errors because coil, input status and holding register commands cannot read input register data. Scaling and Units of Measure The MODBUS data are scaled in English engineering units. All pressures are in psi, temperatures in degrees F,and current in amps. For example, when the CMC Operator User Interface displays the system pressure as 7.73 kg/cm2, the value for system pressure obtained through MODBUS communications is 110 psi. Communication Parameters Configuration of the communication speed (baud rate), parity, number of data bits and number of stop bits is available through the Ingersoll-Rand Service Tool and will be provided by a certified Ingersoll-Rand Service Representative. Date of Issue : August

71 The CMC-DF1 Interface Introduction Customers may want to communicate to the CMC control systems for remote compressor control and monitoring through their Allen-Bradley data highway plus (DH+) network. Adding Allen-Bradley DF1 protocol to the UCM module allows our customers to incorporate our compressors into their plant-wide Allen-Bradley PLC control system. This communication capability also provides for flexibility in the customer's compressed air operation through remote start, stop, and data gathering for preventative maintenance. The customer or his representative must write system software to suit his individual needs for remote control and monitoring. Since the customer writes this interface, the system can be as flexible as the customer desires. One avenue for communicating with the CMC is via DF1 protocol over a full duplex RS- 422 link. This requires an Allen-Bradley interface module 1770-KF2 to link our intelligent RS-422A asynchronous device, Universal Communication Module (UCM), to the Allen- Bradley DH+ network. The CMC Micro controller can communicate with other devices over a variety of communication standards. Supported standards, or protocols, include RS-232, IRBUS (Ingersoll-Rand Proprietary), Modicon s MODBUS, and Allen-Bradley DF1. The built-in ports of the CMC s Universal Communication Module access communications. This UCM-DF1 Interface defines the message structure that a CMC Micro controller uses to exist on a DH+ network. This interface will allow the DH+ network to gather information and control the compressor. The information presented in these sections that follow do not include the Allen-Bradley DF1 protocol details. Detailed information can be obtained from Allen-Bradley Publication October DF1 Protocol and Command Set Reference Manual and Data Highway or Data Highway Plus Asynchronous (RS-232-C or RS-422- A) Interface Module (Cat. No KF2) User s Manual. A DH+ link implements peer-to-peer communication with a token-passing scheme to rotate mastership among the nodes connected to that link. In order to communicate over Allen-Bradley DH+ network, an Allen-Bradley 1770-KF2 interface module must be used. The 1770-KF2 always acts as one node on the DH+ network, which translates DH+ messages to DF1 format, and passes these messages on to the UCM on the RS-422A asynchronous end, or vice versa. The following is a picture of 1770-KF2: Date of Issue : August