Technical Support Information No. 108c January 2013

Transcription

1 Customer Focus Page 1 of 17 Maxum/MicroSAM Modbus Transmission Summary In this documentation is a step by step procedure on how to successfully setup the Modbus transmission for the Maxum and/or MicroSAM gas chromatograph using the Maxum Workstation Software and Database Version 4.1 and later. Common MODBUS communication stack SIEMENS GC s are communicating via RS-232/485 or Modbus on TCP

2 Customer Focus Page 2 of 17 How it works From The Maxum or MicroSAM Analyzer: The Maxum Modus map table can be stored in a Network Access Unit (NAU), Maxum GC, or MicroSAM. In analyser systems with multiple analyzers we recommend installing the Modbus map table in a NAU. Throughout this document, the device containing the Modbus Map will be referred to as the Host Computer Interface (HCI). At the end of a cycle or from a manual transmit command, the NAU, Maxum GC, or MicroSAM will send SQL commands to the HCI s database. The HCI database then updates the modbus_addmap table. Based on the value_type, anlz, app, stream, and result, it knows which address to update with the value received from the Maxum or MicroSAM The modbus_addmap table sends the value to the Modbus Driver. MicroSAM Maxum NAU or Analyzer Modbus_ Addmap table Optichrom Modbus driver Modbus over IP - Ethernet Host RS232 or 485 From the Host: The Host sends a message to the Modbus Driver requesting the value stored at a certain address The Modbus Driver sends the value for the requested address back to the Host, based on the contents of the modbus_addmap table The Host can also direct commands which are routed thru the Modbus Driver and Modbus_addmap table to the local or remote units.

3 Customer Focus Page 3 of 17 How to make it work Must have an address map customized to user specs General address rules: 1. Addresses that range from are read write boolean values (true or false) 2. Addresses that range from are read only boolean values 3. Addresses that range from are read only word values (16 bits) 4. Addresses that range from are read write word values General map rules: 1. Each transmitted result must be defined in the address map 2. Each transmitting application must have a status in the map Map must be limited to ~4000 addresses (database limitation). You will need to know the Analyzer #, application #, stream #, and result # for every result that the system needs to handle. You will also need to know the specific customer requirements for host computer controls and information. See the Formula section to determine if the system can handle the number of addresses required addresses is a good rule of thumb for this limitation, but certain configurations may allow more or less addresses. The reason for this is that a map with more flags defined, as opposed to results, takes up less room than a map with mostly results. The limit for a map with only Analyzer status and results may be less than Note that a much larger map may be successfully loaded, but when the NAU goes through a reset, the database cannot be rebuilt. Configure the Analyzers to transmit results: 1. In each Result set the trtval to a valid number for each result to be transmited 2. In each stream to be transmited set the autotrt flag 3. Add a host entry in the host table of each analzyer designating the Logical ID (LID#) for the HCI containing the desired Modbus Map. Add scale factor (sf) and bad value (bv) entries to the map for scaled result data types as first two entries in map (recommended but not required) Load the map into the HCI device using Maxum Utilities (DBConverter in versions 4.3/5.0 and later) Configure serial communication or use defaults: For versions 4.4 and earlier (Syscon 1/Syscon+) use modbus_setting attribute in the system_control table For version 5.0 and later (Syscon 2) use serial settings table Starting in version Syscon 2) Modbus TCP is available and can be configured by entering TCP in the modbus_setting attribute in the system_control table Verify operation by Simulating the DCS (Master): Use the Mdbus, Modview or other compatible modbus simulation software

4 Customer Focus Page 4 of 17 Simple example 32-bit floating point: Analyzer 124 has 3 applications Application 1 has stream 1, results 1-3 Application 2 has stream 4, results 1-3 Application 3 has stream 1, results 1-3 No control from host is required, Host is not interested in readme flags or any other information from the Analyzers only results and Analyzer status Note that these addresses do not comform with the HCI-H (Optichrom Modbus) Map: host desc data_type address anlz app stream res value_typ init slave1 slave2 EUH tag e value I 1 sf bv R RES R RES R RES R RES R RES R RES R RES R RES R RES I AN 1 22 I AN 1 23 I AN 1 Note: the results are designated here as 32-bit floating point numbers (REAL format). The second addresses(40002,40004,..) are not defined in the map. The host must swap registers to reconstruct the number that it receives. Example: the read message for address requests 2 registers. The returned data is 3F AE swap registers 47 AE 81 3F = Value Types SF = Scale Factor (not used in this map) BV = Bad Value (see Bad Value description below) RES = Result AN = Analyzer Status

5 Customer Focus Page 5 of 17 Simple Example 16-bit scaled: Analyzer 125 has 1 application Application 1 has stream 1, results 1-3 Application 1 has stream 2, results 1-3 Application 1 has stream 3, results 1-3 No control from host is required, Host is not interested in readme flags or any other information from the Analyzers only results and Analyzer status Note that these addresses do comform with the HCI-H (Optichrom Modbus) host tag desc data_type address anlz app stream res value_type init value slave slave2 euhiref 1 sf bv I AN S RES S RES S RES S RES S RES S RES S RES S RES S RES E EU E EU E EU E EU E EU E EU E EU E EU E EU Note: there results are designated here as 16-bit scaled numbers (SCALED format). Each result has one address and an associated EUHI address for its full scale range. The actual scaled value transmitted is determined from the formula (Result/EUHI) x Scale Factor = Scaled Result Example: Result = 5.4, EUHI = 10 (5.4/10) x 9999 = = bit Value = h Value Types SF = Scale Factor (for scaling transmitted values) BV = Bad Value (see Bad Value description below) RES = Result AN = Analyzer Status EU = EUHI (Engineering Units High range full scale)

6 Customer Focus Page 6 of 17 Detailed procedure NAU or GC is the HOST Note: In the procedure outlined below, the Host Computer Interface (HCI) refers to the device (NAU or GC) where the Modbus map is loaded. Add a Host Computer Interface record to the GC s host table Connect to the Maxum or MicroSAM. Display the host table: [system tables] > [host]. Add an entry to the host table: From the Main Menu select [edit] > [add record]. From the Add Record dialog box enter the host_id. Typically host_id s start at 1 and continue sequentially. Entering a host_name is optional. Connect to the Maxum or MicroSAM. Display the Hosts Settings table on the Analyzer Network Hosts screen : [Analyzer View] > [Network] > [Hosts]. Add an entry to the Host Settings table : {Host Settings tab} > [Add]. The next available Id is automatically selected but can be modified in the Properties section. Entering a Name for the host entry is optional. Set the Host Computer Interface protocol type in the host record Edit the type attribute in the host table. Display the host table: [system tables]> [host]. Select the type attribute from the host record. Enter the protocol number in the type field. For Maxum Modbus set type = 6 (6 =Maxum Modbus, 7=Maxum Modbus freeform).

7 Customer Focus Page 7 of 17 On the Analyzer Network Hosts screen, edit the Type property of the Host Settings table. Display the Host Settings table: [Analyzer View] > [Network] > [Hosts]. In the Type property, click on [ ] to display a list of the available types. For Maxum Modbus select Modbus (or Modbus free form if needed). Enter the reference to the HOST device in the host record Anlzref is an attribute or column in the host table, host record and should contain a logical reference to the Host Computer Interface (HCI). A logical reference or LID is a system unique, user assigned, numerical value used to reference a particular device. Anlzref must be assigned the HCI s LID. First determine the HCI s LID. Then, using System Manager display the host table: [system tables] > [host]. Click on the host record s anlzref column created in step #1 to display a drop-down list box. Click on [ ] to display a list of the available devices (LID). Scroll down and select the HCI s LID. If the HCI s LID does not show up in the list, wait ten minutes. System Manager will automatically update the list when a device broadcast is received. Each Analyzer or NAU broadcasts its LID every ten minutes. On the Analyzer Network Hosts screen, the Analyzer Id property of the Host Settings table should contain a logical reference to the Host Computer Interface (HCI). A logical reference or Logical ID is a system unique, user assigned, numerical value used to reference a particular device. The Analyzer Id property must be assigned the HCI s LID. First determine the HCI s LID. Then, using GCP, display the Host Settings table: [Analyzer View] > [Network] > [Hosts]. In the Analyzer Id property, click on [ ] to display a list of the available devices (Logical ID). Scroll down and select the HCI s Logical ID. If the HCI s Logical ID does not show up in the list, wait ten minutes. GCP will automatically update the list when a device broadcast is received. Each Analyzer or NAU broadcasts its Logical ID every ten minutes. Set the host to enable transmission of results Edit the host_def attribute in the host table. Display the host table: [system tables] > [host]. Set the host_def attribute equal 1 to enable the transmission of results to the HCI. Results can be sent to multiple HCI devices by setting host_def equal to 1 in each host table record. System Manger Example: HCI owns the LID 25 and IP On the Analyzer Network Hosts screen, edit the Enabled property of the Host Settings table. Display the Host Settings table: [Analyzer View] > [Network] > [Hosts]. Check the box for the Enabled property to enable transmission of results to the HCI. Results can be sent to multiple HCI devices by checking the Enabled box in each Host Settings table record.

8 Customer Focus Page 8 of 17 GCP Example: HCI owns the Logical Id 34 and IP Set streams to transmit Setting the autotrt attribute in the stream_method table enables the automatic transmission of results at the end of each cycle. Display the stream_method table [application] > [tables] > [stream_method]. Set the autotrt attribute equal to 1. Set autotrt on each application/stream of interest and for the calibration/validation streams, else the modbus table will transmit a BAD VALUE to the DCS while in calibration/validation mode! System Manager Example: On the Application Sequences screen, setting the Auto Transmit Result property of the Stream/Method Settings table enables the automatic transmission of results at the end of each cycle. Display the Stream/Method Settings table: [Application View] > [Sequences] > {Stream/Method Settings tab}. Check the box for the Auto Transmit Result property on each application/stream of interest and for the calibration/validation streams, else the modbus table will transmit a BAD VALUE to the DCS while in calibration/validation mode! GCP Example:

9 Customer Focus Page 9 of 17 Set results to transmit in the result table The trtval attribute, located in the result table, defines the order results are sent to the HCI. Modify the trtval attribute for each stream/result to be sent to the HCI. Trtval values can be assigned in any order provided the sequence starts with a 1 and no numbers are skipped in the sequence {i.e. valid sequence = 1,2,3,4 invalid sequence = 2,3,4,6 (no 1 or 5 in sequence)}. Duplicates are not allowed within a particular stream. Repeat this step for each application/stream. Display the result table [application] > [tables] > [result]. Assign each application/stream/result a sequential integer value based on the desired transmission order. Save and close the result table. System Manager Example: 7 results are transmitted to the HCI sequentially based on trtval order. On the Application Results screen, the Transmit Value property of the Result Configuration table defines the order results are sent to the HCI. Modify the Transmit Value property for each stream/result to be sent to the HCI. Transmit Value entries can be assigned in any order provided the sequence sequence starts with a 1 and no numbers are skipped in the sequence {i.e. valid sequence = 1,2,3,4 invalid sequence = 2,3,4,6 (no 1 or 5 in sequence)}. Duplicates are not allowed within a particular stream. Repeat this step for each application/stream. Display the Result Configuration table: [Application View] > [Results] > {Result Configuration tab}. Modify the Transmit Value property and assign each application/stream/result a sequential integer value based on the desired transmission order. GCP Example: 10 results are transmitted to the HCI sequentially based on Transmit Value order.

10 Customer Focus Page 10 of 17 Alternate Method using GCP An alternate method exists for editing the Transmit Value of multiple results without needing to select each result and edit the value under the Properties section. Open the Edit order Values dialog box: [Application View] > [Results] > {Result Configuration tab} > [Edit order Values]. Select the result to modify and then enter the desired order in the Transmit Value attribute or column for each desired result to be transmitted. It is also possible to select all results <Select All>, or multiple results by selecting the first result then pressing <SHIFT> on the keyboard and simultaneously selecting the last result desired. Next enter a Start Value, select the checkbox for TransmitVal and <Apply>, which will automatically update the selected results sequentially. After modifying the values, select <OK> to update the result table (may be off the screen at the bottom). GCP Alternate Method Example:

11 Customer Focus Page 11 of 17 The next step is only needed when using Advance Optichrom Analyzers with Maxum Modbus. You need at least an ANCB_EN card implemented in the Maxum HCI or a Gateway (ANG_EN) to transmit the Optichrom Modbus (HCI-H) results from the Advance Optichrom Analyzer. Assign a Loop and Unit number to the HCI. The HCI must have a loop and unit number defined to communicate with Advance Optichrom devices. ADH addressing consists of a Loop (subnetwork) (1-8) and Unit (device address) (1-31) number. Edit the loop and unit attributes located in the system_control table. Display the system_control table: [system tables] > [system_control]. Select the loop column and enter a valid Loop number {1-8}. Then select the unit column and enter a valid Unit number {1-31}. On the Analyzer Network screen, edit the loop and unit properties of the Advance Data Hiway Settings table. Display the Advance Data HiwaySettings table: [Analyzer View] > [Network] > {Advance Data Hiway tab}. Select the Loop field and enter a valid Loop number {1-8}. Then select the Unit field and enter a valid Unit number {1-31}. Verify ADH transmit format setting The adh_trtformat attribute in the system_control table defines how the Maxum database handles the incoming Optichrom TRT message. It must be set to HCIH format for the Maxum HCI to properly load the appropriate data into the database and map. Edit the adh_trtformat in the system_control table. Display the system_control table: [system tables] > [system_control]. Select the adh_trtformat column and enter the value for HCIH {0}.. System Manager Example: HCI owns LID 25, loop 1, unit 25, and shows HCIH {0} as adh_trtformat On the Analyzer Network screen, the Format property of the Advance Data Hiway Settings table defines how the Maxum database handles the incoming Optchrom TRT message. It must be set to HCIH format for the Maxum HCI to properly load the appropriate data into the database and map. Edit the Format setting of the Network table. Display the Newtork table: [Analyzer View] > [Network] > {Advance Data Hiway tab}. In the Format field, click on [ ] to display the list of available formats and select HCIH (or the correct choice) from the list. GCP Example: HCI owns Loop 1, Unit 2 and shows HCIH as Format

12 Customer Focus Page 12 of 17 Modify Optichrom Transmit Event to Address of Maxum HCI Modify the Advance Optichrom Analyzer(s) XMIT RESULTS event (usually Event 32), to change the TRT statement to use the Loop and Unit number assigned to the Maxum HCI. These are the last two numbers in highlighted lines below. Example of an Advance Optichrom Analyzer XMIT RESULTS event modification to match Maxum HCI Loop 1, Unit 25: Event 32 0 DECL EVT,32,UN,255,"XMIT RESULTS",STRMS=ALL 10 REM "THIS EVT IS SCHEDULED BY EVT 1" 20 LET J = F(191) 30 LET R(J+4,N) = F(190)/99*C(5) 40 LET R(J+5,N) = C(268) 50 LET R(J+6,N) = C(269) 60 LET R(J+11,N) = 256*F(193,N)+C(3) 70 LET R(J+9,N) = R(J-1,N) 80 IF R(J+9,N) < 800 THEN IF C(178) = 0 THEN LET R(J+9,N) = IF R(J+9,N) < 600 THEN IF C(179) <> 2 THEN IF C(178) = 0 THEN LET R(J+9,N) = 600+C(2) 150 GOTO LET R(J+9,N) = 700+C(2) 170 IF C(179) <> 0 THEN LET R(J+9,N) = LET K = F(99)* LET L = F(191) 210 LET R(J+12,N) = R(J+9,N) 220 LET R(J+9,N) = F(190)/999*R(J+9,N) 230 REM " TRT N,K,L,2,30" 232 DELAY TRT N,K,L,1, END Note: The modification above can be accomplished with APC Table Editor, or by using the ADBmake and ADBlist utilities provided with APC software along with any text editor. See APC help for instructions. This modification can also be done using a Portable Service Panel in the Application Mode.

13 Customer Focus Page 13 of 17 Load the Modbus address map using System Manger Workstation Versions 4.2 and earlier s Load MODBUS utility (located under Tools/Maxum Utilities/Loader/Load MODBUS) to add the address map to the HCI database. See description below Workstation Versions 4.3/5.0 and later s DBConverter utility (located under Tools/Maxum Utilities/Loader/DBConverter) to add the address map to the HCI database. See description below. System Manager Example: HCI receives scaled data from Optichrom analyzer 17 Load the Modbus address map using GCP Workstation Versions and later, select System Manager s DBConverter utility (located under Tools/Start DBConverter) to add the Modbus address map to the HCI database. See description below. GCP Example: HCI receives scaled data from Optichrom analyzer 125

14 Customer Focus Page 14 of 17 Configure the HCI serial communication port for DCS communications using System Manager Versions 4.4 and earlier Display the system_control table: [system tables] > [system_control]. Enter a value in the modbus_setting attribute based on the following parameters. Y = serial port address (1 for RS-232, 2 for RS-485) a = baud rate (50, 75, 110, 134, 150, 200, 300, 600, 1200, 1800, 2400, 4800, 9600, 19200, 38400) b = parity (e, o or n) c = data bits (8 only) d = stop bits For Maxum: Y:a,b,c,d(example--1:19200,n,8,1 or 2:19200,n,8,1) For MicroSAM: (4.1 and earlier only) Y is COM1(example--COM1:19200,n,8,1,485 or COM1:19200,n,8,1,232) Versions 5.0 and later Display the serial_settings table: [system tables] > [serial_settings]. Enter a value in the appropriate portnum record based on the following parameters. a = baud rate (50, 75, 110, 134, 150, 200, 300, 600, 1200, 1800, 2400, 4800, 9600, 19200, 38400, or ) b = parity (e for even, o or odd, or n for none) c = data bits (7 or 8) d = stop bits (1 or 2) e = flow control (h for hardware, n for none) f = 232 for RS-232, 485 for RS-485 For Maxum: a,b,c,d,e,f (example ,n,8,1,n,232 or19200,n,8,1,n,485) For MicroSAM: (latest DB version ) still uses modbus_setting entry as outlined above for version 4.4. Configure the HCI serial communication port for DCS communications using GCP Display the Analyzer Network Serial Settings table: [Analyzer View] > [Network] > [Serial Settings]. Under Details, click on [ ] in each field and select the appropriate setting from the drop down list. These include: Versions 4.4 and earlier Port Number = (RS-232 or RS-485, automatically sets modbus_setting attribute to 1 for RS-232 or 2 for RS-485) Baud Rate = (50, 75, 110, 134, 150, 200, 300, 600, 1200, 1800, 2400, 4800, 9600, 19200, 38400) Parity = (None, Odd, Even) Data Bits = (8 only) Stop Bits = (1 or 2) Versions 5.0 and later Port Number = Port number selected in table {Port 1, Port 2 ( and later Port3 and Port4)} Buad Rate = (50, 75, 110, 134, 150, 200, 300, 600, 1200, 1800, 2400, 4800, 9600, 19200, 38400, 57600, ) Parity = (None, Odd, Even) Data Bits = (7 or 8) Stop Bits = (1 or 2) Communication Standard = (RS-232 or RS-485) Important note: The MicroSAM needs a reboot after configuring the COM 1 port for either RS-232/RS-485 and/or the baud rate adjustment. If you just make a change and don t reboot, the adjustments would not be active.

15 Customer Focus Page 15 of 17 Configure the HCI for Modbus TCP DCS communications Beginning on Workstation version (DB version ), support for Modbus TCP was introduced as an additional DCS communication option. This allows the use of standard TCP/IP communication to a single DCS master from multiple HCI slaves. This also allows for multiple DCS masters on a single communication system and can be used in conjunction with serial Modbus. Display the system_control table [system tables] > [system_control]. Enter TCP (without quotes) into the modbus_setting attribute. System Manager Example: On the Analyzer Network screen, display the Network Settings table: [Analyzer View] > [Network] > [Network Settings]. Check the Enable Modbus TCP checkbox (not shown for DB revisions prior to ) GCP Example:

16 Customer Focus Page 16 of 17 How to create and modify a Modbus Address Map The Maxum Modbus Address Map is a text file used by the Network Access Unit (NAU) or an Analyzer to map Analyzer results to Modbus addresses (registers and coils) for Host computer access. An Address Map is typically created with Microsoft Excel then downloaded to the NAU/Analyzer using Maxum Utilities software (DbConverter in later versions). Once the Address Map has been loaded onto the NAU/Analyzer, it may be viewed and edited with Maxum System Manager, or recently released GCP software. The recommended procedure for adding records or making other significant changes to the Modbus Map is to export the map to a text file, modify the text file, then re-load the file. The modbus text files should always be saved as comma separated file types (i.e. CSV types in Microsoft Excel). Modifying using System Manger Versions 4.2 and earlier UnLoad (save) the Address map file using Maxum Utilities: select [Tools] > [Maxum Utilities] > [Loader] > [Modbus UnLoad]. When the Modbus Address map unload dialog box is displayed, select the correct analyzer from the list, browse to the desired location and enter the desired saved file name in the File name list box. Using Microsoft Excel (CSV file type) or any standard text editor modify the saved Address map file. Load (download) the edited address map file back to the NAU/Analyzer. select [TOOLS]>[Maxum Utilities]> [Loader]>[Modbus Load]. Versions 4.3/5.0 and later UnLoad (save) the Address map file using Maxum Utilities: select [Tools] > [Maxum Utilities] > [Loader] > [DBConverter]. When the Maxum Database Converter dialog box is displayed, under Source File select IP Address and type or select the IP address from the drop down list, then press <Connect>. Under Target File select Modbus, then press <Select File>. When the Target Modbus File window is displayed, enter the desired saved file name in the File name list box. Using Microsoft Excel (CSV file type) or any standard text editor modify the saved Address map file. Load (download) the edited address map file back to the NAU/Analyzer. select [Tools] > [Maxum Utilities] > [Loader] > [DBConverter]. Perform same steps as Unload except the Source File and Target File entries are now reversed. Starting in Workstation 4.2, an Add Modbus map dialog box was added to System Manager allow online creation and editing of the Modbus map. This dialog box can be used to create a map line by line and each entry is error checked for valid entries. Modifying using GCP GCP uses DBConverter supplied with Maxum System Manager., connect to the remote HCI and select [Tools] > [Start DBConverter]. Follow the procedure outlined above for versions 4.3/5.0 and later using the GCP path to DBConverter. Another method for creating a new map is to modify an older map using Microsoft Excel (CSV file type) or any standard text editor, then save as a new name.

17 Customer Focus Page 17 of 17 Using Bad Value A bad value is used, when defined in the map, when a condition on the analyzer suggests that the values are not current or good. These conditions are: the result exceeds the EUHI the EUHI has changed the analyzerstatus is equal to 100, (error must be in stream table, marks all results for stream as bad) the analyzer status is < 500 and > 100 (marks all results for analyzer as bad) the analyzerstatus is < 100 (in hold, out of service, or expected results timeout expired; marks results for all streams on the application as bad) the stream is disabled (marks all results for stream as bad) If the bad_value in the map is > 0 there will be the normal process of setting values bad. Usually the bad value is defined as (bad quality indicator). Using the value 0 freezes the actual results in the result table if the conditions mentioned above occur. So, no bad value processing is done. Note: for Optichrom analyzers, all bad values are determined by the analyzer database programming.