Open Processor with Modbus Master Driver Owner s Manual Rev. 1, 6/98

Transcription

1 Open Processor with Modbus Master Driver Owner s Manual Rev. 1, 6/98

2 Rev. 1, June 1998 NOTICE The information contained within this document is subject to change without notice and should not be construed as a commitment by Landis & Staefa, Inc. Landis & Staefa, Inc. assumes no responsibility for any errors that may appear in this document. All software described in this document is furnished under a license and may be used or copied only in accordance with the terms of such license. WARNING This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instructions manual, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference in which case users at their own expense will be required to take whatever measures may be required to correct the interference. SERVICE STATEMENT Control devices are combined to make a system. Each control device is mechanical in nature and all mechanical components must be regularly serviced to optimize their operation. All Landis & Staefa, Inc. branch offices and authorized distributors offer Technical Support Programs that will ensure your continuous, trouble-free system performance. For further information, contact your nearest Landis & Staefa, Inc. representative. Copyright 1998 by Landis & Staefa, Inc. TO THE READER A Reader Comment form is located at the end of this manual. Please use this form for reporting errors or discrepancies. Insight for Minicomputers is a registered trademark of Landis & Staefa, Inc. Insight for Personal Computers is a registered trademark of Landis & Staefa, Inc. Printed in U.S.A.

3 Table of Contents Introduction About this Manual Prerequisites Compatibility Principles of Open Processor Operation Gathering and Processing Field Inputs Executing Control Programs Processing Operator Commands Building Level Network Single Open Processor Remote Sites Hardware Modbus Overview Open Processor Applications Modbus Data Organization Overview Supported Modbus Protocol Functions Understanding Modbus Addressing Files Register Register Addressing Modbus Address Offset Supported Data Types Supported Modbus Parameters Supported Modbus Protocol Functions Supported Communication Parameters RS-485 Communications RS-232 Communications RS-422 Communications Project Requirements Physical Connection Database System Configuration System 600 Components Modular Building Controller or Remote Building Controller Enclosure Open Processor Open Processor LEDs Other Open Processors Power Module, Controller Module Expansion Module Kit Point Termination Modules Operator Interfaces Operator terminals Video Display Terminals and Printers Modems i

4 Open Processor with Modbus Master Driver Owner s Manual Software Overview Open Processor Software Modbus Master Driver Operator Interface PPCL Point Database Overview Logical Points Physical Points Virtual Points Point Definition Information Point Name Point Types Point Descriptor Alarm Information Point Address Modbus Addressing Totalize Information Engineering Units Slope and Intercept Constants Sensor Types COV Limit Initial Value English, SI Units Override Time Normally Closed Invert Value Point Termination Module Points Dynamic Point Information Current Value Point Condition Command Priority Enhanced Alarm Priority Digital Value Totalized Value Metadrop Point Addresses (Mapping the Metadrop) Required Points Applications Overview Open Processor Applications Modbus Data Organization Overview Supported Modbus Protocol Functions Understanding Modbus Addressing Files Register Register Addressing Modbus Address Offset ii

5 Table of Contents Supported Data Types Point Database Guidelines Point Addresses Metadrop Point Addresses (Mapping the Metadrop) Troubleshooting Overview Basic service information Ordering replacement parts Open Processor Troubleshooting Open Processor Operation Trunk Interface II RS-422 to RS-485 Converter Point Operation Communications with Modbus System Battery Replacement Procedure Required tools Instructions Glossary...Glossary-1 Index...Index-1 iii

6 Open Processor with Modbus Master Driver Owner s Manual iv

7 Introduction 1 About this Manual This manual is written for the owner and user of the System 600 Open Processor with Modbus Master driver, referred to as Open Processor for the remainder of this manual. It is designed to help you become familiar with the Open Processor and its applications. The manual contains the following information: Section 1, Introduction, describes each section in this manual and presents an overview of Open Processor operation. Section 2, Hardware, describes and explains the function of the Open Processor and related hardware. Section 3, Software, describes the software contained in the Open Processor. Section 4, Point Database, defines the Open Processor s point database. Section 5, Applications Section 6, Troubleshooting, describes basic corrective measures to take if you encounter a problem when using the Open Processor. This section is not intended to serve as a full diagnostic guide. Rather, it is designed to address basic troubleshooting issues. If you encounter a problem not covered in this section or require further assistance, consult your local Landis & Staefa representative. A Glossary describes the terms and acronyms used in this manual. An Index is provided to help you locate information presented in this manual. 1-1

8 Open Processor with Modbus Master Driver Owner's Manual Figure 1-1 shows an Open Processor. Figure 1-1. The Open Processor Prerequisites In addition to reading this owner's manual, you should also become familiar with the following technical documents. Each document has been written to help you get the most use out of your Open Processor. Powers Process Control Language (PPCL) User's Manual, product number This manual describes PPCL, the language used to write the control programs for the Open Processor. Field Panel User's Manual, product number This manual describes the operator interface program used to communicate with the Open Processor and other System 600 field panels. Field Panel User's Quick Reference Guide, product number This guide is a pocket version of the Field Panel User's Manual written for experienced users of the operator interface. It contains a listing of the operator interface prompt strings and the keystrokes an operator needs to access the functions. These manuals along with information about other products, services, and technical training classes can be obtained from your local Landis & Staefa representative. Compatibility The Open Processor is fully compatible with the following System 600 products: Insight for Personal Computers Insight for Minicomputers Stand-alone Control Unit (SCU), Revision 6.1 or greater* Local Area Network (LAN) Controller* Remote Control Unit Protocol 2 (RCU P2)* Modular Building Controller (MBC) Remote Building Controller (RBC) Floor Level Network (FLN) Controller * To view all the features of the Open Processor from this field panel's operator interface, the field panel must have Revision 12 or greater firmware. 1-2

9 Introduction Principles of Open Processor Operation Gathering and Processing Field Inputs Executing Control Programs Through the floor level network port, the Open Processor establishes communication with and gathers information about the Modbus system it monitors and controls. Updated information received from the Modbus network is stored into a standard System 600 point type. The Open Processor also executes control programs, handles operator commands and requests, and makes control management decisions. The Open Processor samples the Modbus network inputs, or points, for information and stores numerical representations of these values. The Open Processor then takes the required action; that is, it either adds current information to the history file or sends an alarm message to the proper location. The Open Processor continuously executes a user-defined set of instructions called the control program. This program uses the most recent point values and the most recent clock time. The control program performs the following functions: evaluates control strategies uses an internal calendar and time clock for time-based functions updates point values, and commands field points according to the program results sends alarms, messages, or reports to proper terminal locations as needed Processing Operator Commands An operator can issue commands or requests to the Open Processor using an operator terminal and the operator interface program that resides in the Open Processor. The functions that an operator may perform depend upon the operator s assigned access level. The operator access levels and the functions they support are listed in Table 1-1. Table 1-1. Operator Access Levels and Functions. Function Level 0 Level 1 Level 2 Display and list points Command points Enable and disable points Perform basic PPCL functions Edit the point database Perform advanced point commands Create schedules Perform advanced PPCL functions Perform networking functions = function supported at this level 1-3

10 Open Processor with Modbus Master Driver Owner's Manual Valid operator commands to change point values or to command field points are handled similarly to field input or control program commands. For example, if an operator issues an ON command to a fan starter, the Open Processor issues the ON command to the field point and updates the value in its memory. In this case, the operator overrides the control program. The fan point would remain ON until the operator commands the fan OFF or until the operator releases the point back to automatic control. NOTE: Either the Open Processor or the Modbus controller can command field devices. Building Level Network Up to 94 Open Processors and field panels can be connected on a building level network (BLN), also known as a Protocol 2, P2, or peer-to-peer network. Information from any Open Processor or field panel on the BLN can be accessed and shared. The BLN provides connections within or between buildings by using physical wire, dedicated telephone lines, or dial-up telephone lines. More than one operator can access the network at one time. For example, as one operator accesses the system, another operator can access the system at another terminal or from a remote site by using a modem. Alarms are reported to the alarm printer even as an operator accesses information. When an operator issues a command over the network, the Open Processor or field panel at which the operator issued the command validates the command, determines the command s destination, and passes the command to the destination over the network. This process is illustrated in Figure 1-2 as follows: a command, issued by the operator at the Open Processor located in the lower level of the building, is sent through the BLN to the Open Processor located on the penthouse to control the main air handling unit of the building. For more information about networking, contact your local Landis & Staefa representative. Single Open Processor Remote Sites The Open Processor can operate as a stand-alone controller. A single Open Processor is typically used in remote sites where only the equipment for that site needs to be controlled. Communications with the remote site is achieved using modems. The remote-site Open Processor can initiate a telephone call to a printer, a dumb terminal, or a minicomputer or personal computer running Insight software. Once the remote site connects to the device, an alarm or other user-defined event is issued. When the remote site no longer requires the connection to the device, the remote site disconnects. The remote site can also receive telephone calls from a device running Insight software to allow centralized access of a local network database. For more information about remote site Open Processors, contact your local Landis & Staefa representative. 1-4

11 Introduction Figure 1-2. Commanding Over a Network 1-5

12 Open Processor with Modbus Master Driver Owner's Manual Notes 1-6

13 Hardware 2 Modbus Overview Modbus refers to a protocol that has become an industry standard. The protocol was developed to exchange data between programmable logic controllers (PLCs). It was made publicly available, and, due to its simplicity, was adopted by many manufacturers for use in their own products. Currently, there are thousands of manufacturers around the world whose products communicate using Modbus. It is primarily used in the commercial and industrial controls industry. There are two types of Modbus protocol: ASCII and RTU. Most products and systems today, including Landis & Staefa's Open Processor with Modbus Master driver, support the RTU version. Modbus is a Master/Slave protocol, in which one Master device polls one or more slave devices for data and issues commands to the slaves (when applicable). None of the slaves can initiate communications with each other or the master. The slaves communicate only when prompted by the master. Every Modbus network will support only a single master. The Open Processor with Modbus Master driver, referred to as Open Processor for the remainder of this document, can act as a master only. Landis & Staefa has developed a generic Modbus master driver so that communications with many different third-party, Modbus slave devices is possible. Although the Modbus specification is publicly available and has achieved true standard status, manufacturers are free to implement the protocol in a manner that fits their particular product or architecture. As a result, there are products and systems which support the Modbus RTU protocol which may not be compatible with our Open Processor. For a list of Modbus functions, refer to Table 2-1. If compatibility with a third-party device using Modbus is not specifically mentioned in the Integrated Systems Guidebook or the System 600 Open Processor Drivers Applications Manual ( ), consult the Home Office. Even though a particular product or system is compatible with the Open Processor, the amount of effort required to integrate to the device can vary. In addition, performance can vary. Consult the Home Office when in doubt. Our field offices have a great deal of experience with integration, which makes drivers such as this very easy to install and commission. However, as with any driver, this requires knowledge of the other system so that the mapping of points can be accomplished accurately. With Modbus integration, this is especially important, since expensive processes or equipment may be involved. 2-1

14 Open Processor with Modbus Master Driver Owner's Manual Open Processor Applications Typical applications include a customer who has a number of Modbus Device points (less than 2000) which are required to be monitored on Insight for alarming and trending purposes. Commanding, when applicable, is also possible through Insight. High-speed sequential logic control, where Modbus device points are automatically commanded using PPCL, is not recommended. Some applications require a Modbus device to receive System 600 (S600) point values. For example, a drug manufacturing process needs the temperature and humidity for each cell (monitored by S600), and will shut down if these values rise or fall out of the specified range. This is an acceptable application because it doesn t use sequential logic control. Since the Open Processor acts as the master, the driver will periodically write (command) the Modbus device registers using PPCL routines (frequency depends on customer s specifications). CAUTION: Incorrect point commanding and operation may damage the devices that are controlled by this Open Processor. Points that may be commanded for specific devices must not be set to values other than those recommended by the Foreign System Device Manufacturer. Refer to the Foreign System device documentation for specifics on that devices operations. CAUTION: There may be more than one source of control for points in the Foreign System device. Be sure not to command points that are being commanded by other connected devices. Also, be sure that the real-times for the Connected Foreign System device network and the Landis & Staefa network are synchronized. CAUTION: If you try to command an LAO point value below the minimum limit, the system makes the value match the minimum limit. If you try to command an LAO point value above the maximum limit, the system makes the value match the maximum limit. If you need further information, consult with your local Foreign System device representative 2-2

15 Hardware Modbus Data Organization Overview In order to make the following sections more meaningful, an overview of Modbus data organization is shown in Figure 2-1. Each Modbus Slave has a unique Device ID (address). The slave device s memory space can be described as groups of similar data, each accessed by a specific function code and located in a specific Modbus address range. Refer to Table 2-1 for Function Code and address range details. MODBUS DEVICE #1 DEVICE #2 DEVICE #32 DEVICE #1 AREA (01) AREA (02) AREA (03) AREA (04) AREA (01) REGISTER (01) REGISTER (02) REGISTER (03) REGISTER (04) REGISTER (05) REGISTER (06) REGISTER (07) REGISTER (XX) GW0307R1 (MOST SIGNIFICANT BIT VALUE) (LEAST SIGNIFICANT BIT VALUE) Supported Modbus Protocol Functions Figure 2-1. Modbus Addressing Top Level Down. Table 2-1 shows the Modbus protocol functions supported by this Open Processor. Table 2-1. Modbus Functions Supported. Function Code Modbus Protocol Description Modbus Address Range 01 Read Coil Status Read Input Status Read Holding Registers Read Input Registers Force Single Coil Preset Multiple Registers

16 Open Processor with Modbus Master Driver Owner's Manual Understanding Modbus Addressing Files The purpose of this section is to help the Landis & Staefa customer understand how Modbus data elements are addressed. This discussion refers to, and expands on, Figure 2-1. Within each Modbus slave device, there are groups of data (Figure 2-2) that are organized by the Modbus Function Code used to access the data. The Open Processor supports the Modbus Function Codes shown in Table 2-1. HOLDING REGISTERS INPUT REGISTERS GW0306R1 COILS BITS Figure 2-2. Areas. Register A register (refer to Figure 2-3) is a group of bits. A bit is a value that can be read by the computer that represents a real-world point value. Registers and bits are addressed in the following format: [Slave ID#] [data type] [Modbus offset]: where: Slave ID = unit s address data type = refer to Supported Data Types section Modbus Offset = identifies where in the address range to begin obtaining data GW0157R1 REGISTER (01) REGISTER (02) REGISTER (03) REGISTER (04) REGISTER (05) REGISTER (06) REGISTER (07) REGISTER (XX) Figure 2-3. Registers. 2-4

17 Hardware Register Addressing BITS (VALUES OF 0 OR 1 ONLY) GW0158R1 (most significant bit) (least significant bit) Figure 2-4. Register Addressing. Registers are made up of combinations of binary values of either one or zero. How the register s value is interpreted depends on the data type specified. Modbus Address Offset Supported Data Types The Modbus Address Offset is a number greater than or equal to one (1) that identifies where the Open Processor begins to obtain data within the range of Modbus Addresses. The Open Processor supports the following Modbus data types and address: The Open Processor supports the following Modbus data types and address: Unsigned Analog INPUT REGISTER (Modbus: ) Signed Analog INPUT REGISTER (Modbus: ) Unsigned HOLDING REGISTER (Modbus: ) Signed HOLDING REGISTER (Modbus: ) INPUT BITS (Modbus: ) OUTPUT COIL (Modbus: Open Processor extensions to the Modbus protocol: Unsigned Double Precision HOLDING REGISTER (Modbus: ) Signed Double Precision HOLDING REGISTER (Modbus: ) IEEE Floating Point HOLDING REGISTER (Modbus: ) Accessing a Bit in a HOLDING REGISTER (Modbus: ) Examples Unsigned Analog Input Register (Modbus: ) Signed Analog Input Register (Modbus: ) 16 bit registers can be interpreted as either signed (IS data type) or unsigned (I data type). To specify a starting register of 30010, use a Modbus offset of 10. Unsigned Holding Register (Modbus: ) Signed Holding Register (Modbus: ) 2-5

18 Open Processor with Modbus Master Driver Owner's Manual 16 bit holding registers can be interpreted as either signed (HS data type) or unsigned (H data type). To specify a starting register of 40001, use a Modbus offset of 1. Unsigned Double Precision Holding Register (Modbus: ) Signed Double Precision Holding Register (Modbus: ) 16 bit holding registers can be combined in pairs of two and interpreted as 32 bit signed long integers (DS data type) or unsigned long integers (D data type). Starting registers must use an odd Modbus Offset (1,3,5,etc). IEEE Floating Point Holding Register (Modbus: ) 16 bit holding registers can be combined in pairs of two and interpreted as 32 bit floating point values (F data type). Starting registers must use an odd Modbus Offset (1,3,5, etc). Accessing a Bit in a Holding Register (Modbus: ) 16 bit holding registers can be interpreted as 16 digital values by using a P data type. Input bits (Modbus: ) The B data type is used to map input bits into the S600 address space. To specify a starting bit of 10020, use a Modbus offset of 20. Output Coil (Modbus: ) Output coils can be mapped to the S600 by using a C data type. To specify a starting coil of 50, use a Modbus offset of

19 Hardware Supported Modbus Parameters Supported Modbus Protocol Functions Supported Communication Parameters Projects may require integration to unique Modbus devices or systems which Landis & Staefa has no experience with. The information in this section is provided to assist in evaluating compatibility with Modbus slave devices. For supported Modbus protocol functions, refer to Table 2-1. Table 2-2 lists the parameters permitted for Modbus communications with foreign devices. Set the parameters of the connected Modbus device accordingly. Table 2-2. Communication Parameters. Parameter Acceptable Values Baud Rate 300, 1200, 2400, 4800, 9600, and 19,200 bps Data Bits 8 Stop Bits 1 Parity None Modbus slave devices support RS-485, RS-232, or RS 422 communications. The use of external devices to provide the appropriate electrical characteristics are described in the following three pages. 2-7

20 Open Processor with Modbus Master Driver Owner's Manual RS-485 Communications RS-485 communications are supported directly by the FLN1 port on the Open Processor (refer to Figure 2-5). This is a common means of communication when multiple Modbus Slave devices are networked in a multi-drop (daisy chained) configuration. RS-485 communications is sometimes referred to as 2-wire, RS-485. Some devices will appear to be RS-485, but will use four wires. In such a case, refer to the RS-422 Communications section for details on connecting to 4-wire, RS-485 devices. S - + FLN 1 OPEN PROCESSOR RS-485 TRUNK CABLE (MAX 4000' / m; STANDARD 24 AWG LOW CAPACITANCE) TWO TWISTED PAIRS (STANDARD 24 AWG LOW CAPACITANCE) COMBINED WITH RS-485 CABLE, MAX LENGTH IS 4000' TAPE BACK SHIELD S - + TERMINAL BLOCK MODBUS DEVICE(S) OR 9-PIN OR 25-PIN CABLE BUILT TO MANUFACTURES SPECIFICATION GW0294R2 TO ADDITIONAL MODBUS DEVICES Figure 2-5. Connecting the Open Processor Directly to Modbus Slave Device(s). 2-8

21 Hardware RS-232 Communications The Trunk Interface II is used to convert RS-232 signals received from a Modbus controller into RS-485 signals for the Open Processor to use, and vice versa (refer to Figure 2-6). S - + FLN 1 OPEN PROCESSOR RS-485 TRUNK CABLE (MAX 4000' / m; STANDARD 24 AWG LOW CAPACITANCE) GROUND WIRE TO EARTH (P/N ) POWER PACK TAPE BACK SHIELD S - + RX TX 7 POWER PMD RS-232 PORT (25-PIN FEMALE) TRUNK INTERFACE II TWO TWISTED PAIRS (STANDARD 24 AWG LOW CAPACITANCE) COMBINED WITH RS-485 CABLE, MAX LENGTH IS 4000' IF OPEN PROCESSOR IS LESS THAN 50 CABLE FEET (15.24 m) FROM MODBUS DEVICE PLACE TRUNK INTERFACE II IN MBC ENCLOSURE TX RX 7 (25-PIN FEMALE) MODBUS DEVICE(S) OR GW0295R2 RX TX 7 (9-PIN FEMALE) Figure 2-6. Connecting the Open Processor to Modbus Slave Device(s) with Trunk Interface II. The following guidelines should be followed when locating the Trunk Interface II: The Trunk Interface II needs a 115VAC power source with a typical 115VAC electrical socket to power the external transformer. If the Open Processor is less than 50 cable feet (15.24 m) from the Modbus controller communications port, place the Trunk Interface II in the MBC/RBC enclosure. This is the recommended placement. If the Open Processor is more than 50 cable feet (15.24 m) from the Modbus controller, place the Trunk Interface II in the Modbus controller cabinet. The TI II requires a standard 120VAC socket as a power source (230V models are also available). Shielded cable is recommended. NOTE: Use the MBC Installation Procedure, Revision 3 ( ) as a standard installation guide. In noisy environments, the RS-232 systems are susceptible to data corruption. 2-9

22 Open Processor with Modbus Master Driver Owner's Manual RS-422 Communications The Trunk Interface RS-422 is an Interface Converter Module used to convert an RS-422 signal into an RS-485 signal for use with the Open Processor (refer to Figure 2-7). RS-422 is also found in a multi-drop (daisy-chained) configuration, but is much less common than RS-485. RS-422 is characterized by duplicate transmit and receive conductors. This module can have a cable run of 1000 feet on both the RS-422 and RS-485 sides. It is a special component available through the Integration Department at the Home Office. S - + FLN 1 OPEN PROCESSOR RS-485 TRUNK CABLE (MAX 4000' / m; STANDARD 24 AWG LOW CAPACITANCE) GROUND WIRE TO EARTH (P/N ) POWER PACK TAPE BACK SHIELD S - + TX- TX+ RX- RX+ POWER PMD TERMINAL BLOCK RS-485 / RS-422 CONVERTER TWO TWISTED PAIRS (STANDARD 24 AWG LOW CAPACITANCE) COMBINED WITH RS-485 CABLE, MAX LENGTH IS 4000' IF OPEN PROCESSOR IS LESS THAN 50 CABLE FEET (15.24 m) FROM MODBUS DEVICE PLACE CONVERTER IN MBC ENCLOSURE MODBUS DEVICE(S) RX- RX+ TX- TX+ TERMINAL BLOCK GW0277R2 TO ADDITIONAL MODBUS DEVICES Figure 2-7. Connecting the Open Processor to Modbus Device(s) with RS-422 / RS-485 Converter. 2-10

23 Hardware Project Requirements Physical Connection When supplying a Modbus connection to a Modbus slave device or group of devices, the following information at minimum is required for successful integration: Determine the physical connection of the target slave device(s). Verify compatibility with the communication parameters in Table 2-2, and determine whether an interface device (RS-232 or RS-422) is required. In many cases, RS-232 communications using the Trunk Interface II requires custom-built cables. Many devices require a special card or interface to communicate using Modbus. In addition, some devices require database modifications in order to make data available through the Modbus interface. Sometimes these changes are required in the factory or are costly and risky when done in the field. Verify the responsible party for this work and plan its implementation as early in the project as possible. Database All Modbus integration projects require you to have detailed information regarding the data that will be obtained from the slave devices. This should be compared with the customer required points to determine the final list of points to be defined. Information for every data element should include the following: Modbus slave ID number Modbus register address Description Data type: coil (binary), holding or input registers (analog) For binary data: on/off condition (example: 1=on, alarm, start; 2=off, normal, stop etc.) For analog data (holding and input registers): data range, engineering units, type of analog data (that is, unsigned, signed floating point data etc.) 2-11

24 Trunk Interface II Power DTR TX PMD RX Trunk Interface II Power DTR TX PMD RX Open Processor with Modbus Master Driver Owner's Manual System Configuration The Open Processor enables the System 600 to communicate with a maximum of 32 physical devices on a Modbus network. The integrated system consists of one or more Modbus devices plus the System 600, linked by the Open Processor and, if necessary, the Trunk Interface II or Trunk Interface RS-422. Figure 2-8 diagrams a typical Modbus and System 600 configuration. A description of system components follows. Management Level Network: Ethernet Insight Operator Workstation Building Level Network: Protocol 2 (P2) MBC with Open Processor - OR - - OR - RS Trunk Interface II RS Modified Trunk Interface II RS RS RS RS RS MULTIDROP RS MULTIDROP GW0252R2 MODBUS DEVICE Max. 32 Physical Devices MODBUS DEVICE MODBUS DEVICE Figure 2-8. Typical Modbus and System 600 Configuration. 2-12

25 Hardware System 600 Components Modular Building Controller or Remote Building Controller Enclosure The Open Processor may reside in any Modular Building Controller (MBC) or Remote Building Controller (RBC) enclosure with an open slot on the communications bus (C-Bus). In addition, the Open Processor: supports Expansion Module Kits does not require a Power Module in the enclosure unless the Open Processor controls Point Termination Modules (PTMs) may reside in an enclosure that contains a Power Module and one or more Controller Modules and/or other Open Processors. Other Open Processors are those capable of supporting one of a variety of communication drivers. NOTE: An MBC or RBC enclosure is FCC-approved for a maximum of four Controller Modules and/or Open Processors. Figure 2-9 shows an MBC enclosure with various modules. Figure 2-9. MBC Enclosure with Door Removed. 2-13

26 Open Processor with Modbus Master Driver Owner's Manual Open Processor The Open Processor is a high-performance, independent controller that is customized to meet your exact building control needs. It controls mechanical equipment and performs specialized applications using Direct Digital Control (DDC). The Open Processor can communicate with System 600 field panels and Insight workstations. It can be implemented as a central monitoring unit or remote site equipment controller. Data about Modbus devices for control, display, logging, alarming, and trending on the System 600 is made available by the Open Processor, shown in Figure 2-10, Figure 2-11, and Figure Points in the Open Processor s database hold information about Modbus devices. The Open Processor cannot communicate with any other FLN devices; for example, Terminal Equipment Controllers. The Open Processor connects to the Modbus system using only the FLN 1 port. However, the Open Processor uses the address space of FLN 1, FLN 2, and FLN 3. Figure Open Processor (Front View). Figure Open Processor (Left Side View). Figure Open Processor (Right Side View). Open Processor LEDs Eight LEDs are located on the front of the Open Processor, but only six are active. Each LED is labeled according to its function. Refer to Table 2-3 and to Figure 2-13 for additional information. 2-14

27 Hardware Table 2-3. Open Processor LEDs. Color Label Description Green FLN TX Open Processor is transmitting information over the FLN 1 trunk. Green FLN1 RX Open Processor is receiving information over the FLN 1 trunk. Green BLN TX Open Processor is transmitting information over the BLN trunk. Green BLN RX Open Processor is receiving information over the BLN trunk. Green STATUS Open Processor is powered up and operating properly when this LED is flashing. Red BATT LOW The Open Processor backup battery is low. Replace the battery. Figure Open Processor LEDs. Other Open Processors Other Open Processors are those capable of supporting one of a variety of communication drivers. Other Open Processors also gather information about building systems that they monitor and sometimes control. The information from the building systems is then stored into standard System 600 point types. For more information about other Open Processors and associated drivers, contact your local Landis & Staefa representative. 2-15

28 Open Processor with Modbus Master Driver Owner's Manual Power Module, Controller Module The Open Processor does not require a Power Module or a Controller Module when it is in an MBC or RBC enclosure. However, Power Modules and Controller Modules can share an MBC or RBC enclosure with Open Processors. NOTE: If an Open Processor controls PTMs, a Power Module is required. For more information about Power Modules and Controller Modules, refer to the System 600 Modular Building Controller and Remote Building Controller Owner s Manual, product number Expansion Module Kit Expansion Module Kits contain communication devices that join the Module Bus (M-Bus) of two sets of MBC or RBC enclosures when the first enclosure reaches its maximum point capacity. The Expansion Module Kit contains two different types of modules: the Primary Module (PM) and the Expansion Module (EM). The PM is installed in the primary panel (an MBC or RBC with the Open Processor or Controller Module). The primary panel is responsible for controlling PTMs installed within that enclosure, as well as any enclosures with Expansion Module Kits joined to the primary panel. The EM is installed in the expansion panel (an MBC or RBC without an Open Processor or Controller Module). The purpose of the expansion panel is to provide extra PTM slots for the primary panel to use. For more information about Expansion Module Kits, refer to the System 600 Modular Building Controller and Remote Building Controller Owner s Manual. Point Termination Modules Point Termination Modules (PTMs) are signal converters that have one, two, or four points. PTMs are the interface between the field equipment and an Open Processor or a Controller Module. Field equipment includes devices that provide information to, or are controlled or monitored by an Open Processor or a Controller Module. All field input and output points are either digital points or analog points such as 4mA 20mA sensors, 0Vdc 10Vdc outputs to control actuators, and pulse accumulators. For more information about PTMs, refer to the System 600 Modular Building Controller and Remote Building Controller Owner s Manual. Operator Interfaces Operator interfaces, such as operator terminals (PCs, laptops), video display terminals, and printers, allow you to communicate with the Open Processor. Operator terminals Operator terminals allow you to communicate interactively with the Open Processor. A keyboard is used for input, and a video screen or printer is used to display (echo) your inputs and the system responses. Operator terminals allow you to do the following: directly control or request information about Open Processor points check the operation of Modbus building controls 2-16

29 Hardware change or override control programs in the Open Processor request and receive a variety of Modbus system and point status reports change the definition of points in the system define the destinations of alarm messages and reports control operator access to the system (set up operator access levels and passwords) create backup copies of user-defined control programs (using a PC or a laptop) transmit messages between operator terminals Video Display Terminals and Printers Video display terminals and printers transmit information from the Open Processor to the operator. These two devices allow you to do the following: receive and print reports receive alarms receive and print alarm messages Modems Modems can transmit data from an Open Processor to an operator interface over telephone lines. Therefore, remote communication between the Open Processor and an operator interface is possible using two modems one at each end of the communication link. For example, an alarm printer can be set up in a building manager's office to receive alarms from an Open Processor that is in a remote location. Modems may be used along with leased telephone lines to link remote Open Processors in a networked system and to link remote Open Processors with a centrally located mass storage device such as a personal computer running Insight for Personal Computers or a minicomputer running Insight for Minicomputers. A modem approved for your application can be installed within the MBC or RBC enclosure. A cable connects the modem's RS-232 port to the MMI/MODEM port on the Open Processor. Refer to Figure If you need more room for the modem, remove the literature pocket by lifting up on the center of the pocket until the ends slide out from underneath the two tabs on both sides. NOTE: The communication speed (baud rate) of the modem and the MMI/MODEM port must match. For more information about modems approved for use with the Open Processor, contact your local Landis & Staefa representative. 2-17

30 Open Processor with Modbus Master Driver Owner's Manual Figure Typical Modem Installation. 2-18

31 Software 3 Overview Open Processor Software This section describes the software that comes installed in the Open Processor. The Open Processor software runs automatically when the Open Processor is powered up. When properly configured, the Open Processor establishes communications with the remainder of the System 600 and the Modbus networks, and begins relaying data. The Open Processor contains the following software: System 600 Modbus Master driver operator interface Powers Process Control Language (PPCL) Modbus Master Driver Operator Interface The Modbus Master driver allows the Modbus system to communicate directly with the System 600. An operator issues commands or requests to the Open Processor using an operator terminal and the operator interface. The operator interface is the software that allows the operator to communicate interactively with the Open Processor. The operator interface is described in detail in the Field Panel User's Manual, product number This manual is designed to help you become familiar with and use the operator interface. It describes the functions necessary for everyday operation of your system, plus the higher level functions for commanding, displaying, editing, scheduling, networking, alarm management, and others. For experienced users of the operator interface, the Field Panel User's Manual Quick Reference Guide, product number , contains a listing of the operator interface prompt strings and the keystrokes necessary to access the functions. PPCL The programming language used with the Open Processor is called Powers Process Control Language (PPCL). PPCL is a powerful programming language developed specifically for controlling Heating, Ventilating, and Air Conditioning (HVAC) equipment. 3-1

32 Open Processor with Modbus Master Driver Owner's Manual The control configuration and control requirements of your system are customized into each application by using PPCL. The applications that you can incorporate into the operation of your system include the following: Alarm Management Auto-Dial/Dial-Up Daylight Savings Time Duty Cycling Enthalpy and Dry Bulb Economizer Control Field Panel/Equipment Controller Coordinator Loop Tuning (available as an option) Peak Demand Limiting (PDL) Start/Stop Time Optimization (SSTO) Time-Of-Day (TOD) Scheduling Trend Data Collection The Powers Process Control Language (PPCL) User's Manual, product number , contains information on designing, coding, and implementing PPCL programs. It lists and defines all PPCL control commands, control applications, syntax, and functionality. 3-2

33 Point Database 4 Overview This section describes the Open Processor point database, including point definition information, dynamic point information, point database structure, point addresses, and slopes and intercepts. Most tasks that the Open Processor performs involve either collecting data from Modbus devices or commanding them. Other tasks require communication and calculations within the control programs using stored information. Operators also need a practical method of commanding and examining points. With the Open Processor, operators use the commands and menu-driven prompts of the operator interface. The point database is created by supplying the Open Processor with logical points and information about the Modbus points. There are two basic classifications of point information that make up the point database: Information used to define Modbus points, and information that is updated or set during operation of the Modbus system. In order to monitor and/or control Modbus devices, points must be added to the point database. For details about defining these points, refer to the point addressing information that follows. For additional information about adding or modifying points in the database, refer to the Field Panel User s Manual, product number Logical Points Logical points are used by the operator and the control programs to reference physical or virtual points for commanding or monitoring Modbus devices and System 600 devices connected to Point Termination Modules (PTMs). Logical points handle functions such as alarming, totalization, conversion of field inputs and outputs to engineering units. 4-1

34 Open Processor with Modbus Master Driver Owner's Manual Physical Points Physical points correspond to the hardware that is connected to the Open Processor. They each have a unique eight-character point address that precisely defines the location of the hardware termination in the system by its network, field panel number, field device, and point termination number. Refer to Table 4-1 for more information. The following point types are supported: Analog Input (AI) Analog Output (AO) Digital Input (DI) Digital Output (DO) Logical Controller (LCTLR) Virtual Points Point Definition Information Virtual points are memory-resident points that do not have any physical terminations. Their point addresses specify imaginary terminations. Virtual points can be defined as digital or analog, and are used by operators or the control programs to hold or store information such as setpoints. Users assign unique alphanumeric names to virtual points. The information used to define a point in the point database is called point definition information. This information describes the characteristics of a point and changes only if you edit the database. The following information describes the various types of information you may be required to supply about a point when you define it in the point database. For information on how to enter point definition information into the point database, refer to the Field Panel User's Manual. Point Name The point name is used by the System 600 and the operator to display and to command all logical point types. Naming conventions allow you to use one to six alphanumeric characters (A Z and 0 9) to reference a logical Modbus point. The name may not contain spaces between the characters. It may not duplicate any name in the list of reserved words (which are words used for special purposes in System 600 control programs). The list of reserved words appears in the Powers Process Control Language (PPCL) User's Manual, product number Each logical point must have a unique name within the Open Processor and across the System 600 network. That is, two logical points on the same network may not have the same name, even if they reside in different field panels. Examples of both correct and incorrect words follow: Correct Incorrect FAN01 FAN 01 (Spaces are not allowed between characters.) FLOPCT FLOW% (% is not a valid character.) SMKALM SMOKE (SMOKE is a reserved word.) 4-2

35 Point Database NOTE: It is not necessary for the Modbus system and System 600 to refer to a single point by the same name. However, for ease of use and maintenance, and if the Modbus system supports the System 600 naming convention, you may wish to do so. Point Types The Open Processor supports the five point types listed previously in the Physical Points section. For additional information, refer to the System 600 Modular Building controller and Remote Building Controller Owner s Manual, product number Each point type requires you to supply a specific set of information about it in the point database. Table 4-1 provides a summary of the information required for each point type. Using other points may result in unreliable point data. Logical Analog Input (LAI) An LAI point provides one analog input point. You can use this point type to receive input signals from sensors such as temperature sensors, flow sensors, and pressure sensors. Logical Analog Output (LAO) An LAO point provides one commandable analog output point. You can use this point type to send output signals to devices such as valve actuators and damper motors. If the vendor system supports this feature, Open Processor LAOs are able to command and monitor a point. You do not have to unbundle two points to perform the same function. Logical Digital Input (LDI) An LDI point type monitors one latched digital input. You can use this point type, for example, to monitor the status of low temperature detectors, flow switches, damper end switches, and limit switches. Logical Digital Output (LDO) An LDO point provides one commandable latched or pulsed digital output for two-state (ON/OFF) control. You can use this point type, for example, to send output signals to switches for occupancy indication. LDO points can also be used to store ON/OFF values. If the vendor system supports this feature, Open Processor LDOs are able to command and monitor a point. You do not have to unbundle two points to perform the same function. Logical Controller (LCTLR) For Open Processors that support it, an LCTLR point type allows you to monitor bundled points. 4-3

36 Open Processor with Modbus Master Driver Owner's Manual Table 4-1. Summary of Point Information Categories by Point Type. Category LAI LAO LDI LDO Point name Point type Descriptor Alarm information Totalize Engineering units Point address Slope Intercept Sensor type COV limit Initial value Normally closed Invert value English units y/n Override time = supported Point Descriptor The point descriptor for a logical point is a string of 0 12 alphanumeric characters or blank spaces. Point descriptors help you to identify points when they are displayed at an operator's terminal or in reports. Point descriptors are not used by the system or the operator to request displays or to command points. Therefore, point descriptors need not be unique and may even be left blank. Examples of point descriptors follow: Point Name Point Descriptor FAN01 SUPPLY FAN 1 FLOPCT FLOW PERCENT 4-4

37 Point Database Alarm Information Point Address The alarm option of a point applies to all logical point types. You can specify whether or not you want the point to be alarmable. When you specify that a point is alarmable, the system may request additional information such as the values of the high alarm limit and the low alarm limit to define the conditions under which the point is put into or taken out of alarm. These conditions vary with point type and the individual point requirements. The Open Processor also allows you to define alarm messages, determine printing locations, and design specific alarm applications. A summary of point information appears in Table 4-1. For more information about alarms, refer to the Field Panel User's Manual. The point address applies to all logical point types. The point address is a unique eight-digit number that defines the exact location of the point. No two point addresses may be the same. The Open Processor uses the System 600 point addressing scheme of TCCLDDPP, as shown in Table 4-2. Table 4-2. System 600 Point Addressing Scheme. Abbreviation Meaning Range Description T Trunk 0 3 Individual BLN network number is always zero unless the point is on a minicomputer. CC Cabinet The cabinet number assigned to the Open Processor (unique BLN network node address). NOTE: It is possible to have more than one node in an enclosure. L FLN 0 3 0: Virtual or PTM points 1 3: Modbus devices DD Drop (FLN 1) 00: Reserved (FLN 1) 01 31: Modbus drops (FLN 2) 00 31: Modbus drops (FLN 3) 00 29: Modbus drops (FLN 3) 30: Metadrop (point 0 reserved) (FLN 3) 31: Diag. & Control drop PP Point These are the individual points defined as needed within each device. Virtual points may use any desired scheme. For information on addressing PTM points, refer to the Field Panel User's Manual. 4-5