Flowserve DDC-100 User Manual

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DDC-100

Direct-to-Host

Programming Guide

FCD LMAIM4019-00

(Replaces 435-23009)

Network Control Systems

Contents

1 Introduction 1

1.1 Premise 1

1.2 Emphasis 1

1.3 Audience 2

2 Direct-to-Host Valve Control 3

2.1 Advantages of Direct-to-Host Control 3

2.2 Deliverables for Successful Direct-to-Host Implementations 4

3 Field Unit Monitoring and Control 5

3.1 Use of Coils and Registers for Monitoring and Control 5

3.2 Modbus 6

3.2.1 Modbus Function Code 01 (Read Coil Status) 7

3.2.2 Modbus Function Code 02 (Read Input Status) 8

3.2.3 Modbus Function Code 03 (Read Holding Register) 11

3.2.4 Modbus Function Code 04 (Read Input Register) 18

3.2.5 Modbus Function Code 05 (Force Single Coil) 18

3.2.6 Modbus Function Code 06 (Preset Single Register) 19

3.2.7 Modbus Function Code 08 (Diagnostics) 23

3.2.8 Modbus Function Code 15 (Force Multiple Coils) 24

3.2.9 Modbus Function Code 16 (Preset Multiple Registers) 24

4 The DDC-100 Network 27

Belden 3074F Speciﬁcations 27 Belden 3105A Speciﬁcations 28 Belden 9841 Speciﬁcations 28

4.1 Field Unit Network Communication Channels 28

4.1.1 Field Unit Network Bypass Relays 29

4.1.2 Field Unit Repeater Circuits 29

4.2 Network Topologies 29

4.2.1 Redundant Loop 29

4.2.2 Single-Ended Loop 31

4.2.3 Single-Line Multi-drop 32

4.3 Network Polling 33

4.3.1 Network Communication Errors 35

4.3.2 Network Communication Examples 36

4.4 Network Control 38

4.4.1 Ladder Logic Routines 38

4.4.2 Software Control Modules (C++ or Visual Basic Program) 38

4.4.3 Personal Computer with a Graphical User-Interface 39

5 Interfacing Hardware for the DDC-100 Network 41

5.1 RS-232 to RS-485 Converters 41

5.1.1 RS-232/RS-485 Control Line Steered Converter (P/N 61-825-0966-4) 43

5.1.2 RS-232/RS-485 Converter with RS-485 Self-Steering (P/N 61-825-1032-4) 45

5.2 RS-485 Connection Direct to the DDC-100 Field Unit 48

6 Programming Recommendations 49

6.1 Monitoring Field Unit Status 49

6.2 Issuing Control Commands 50

A Typical DDC-100 Network Installation Assignments 53

Project supplier responsibilities 53

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Figures

Figure 4.1 – DDC-100 Redundant Loop Network 30 Figure 4.2 – DDC-100 Single-Ended Loop Network 31 Figure 4.3 – DDC-100 Single-Line Multi-Drop Network 33 Figure 5.1 – RS-232/RS-485 Converter Dimensions and Rack Mount Kit 43 Figure 5.2 – RS-232/RS-485 Cable Diagram 43 Figure 5.3 – Front and Back Panels of Steered Converter 44 Figure 5.4 – Front and Back Panels of Self-Steering Converter 46

Tables

Table 3.1 – Field Unit Communication Parameters 5 Table 3.2 – Modbus Function Codes Supported 7 Table 3.3 – DDC-100 Coil Assignments, Modbus Function Code 01 Usage for Digital Outputs 8 Table 3.4 – Status Bit Deﬁnitions 8 Table 3.4 – Status Bit Deﬁnitions (continued) 9 Table 3.5 – Field Unit Register Deﬁnitions 12 Table 3.6 – DDC-100 Coil Assignments Modbus Function Code 05 Usage for Digital Outputs 19 Table 3.7 – Modbus 06 Command and Field Unit Holding Register 40001 20 Table 3.8 – Diagnostic Codes Supported by the DDC-100 Field Unit 23 Table 4.1 – Average Field Unit Response Time 34 Table 4.2 – Average Network Scan Time (seconds) 35 Table 5.1 – RS-232/RS-485 Converter Speciﬁcations 42 Table 5.2 – Steered Converter Assembly (P/N 22300-7591) 42 Table 5.3 – Self-Steering Converter Assembly (P/N 22300-7601) 42 Table 5.4 – RS-232/RS-485 Converter (P/N 61-825-0966-4) DIP Switch Functions 44 Table 5.5 – RS-232/RS-485 Converter (P/N 61-825-0966-4) RS-232 Connector 44 Table 5.6 – RS-232/RS-485 Converter (P/N 61-825-0966-4) RS-485 Connector 45 Table 5.7 – RS-232/RS-485 Converter (P/N 61-825-0966-4) Jumpers 45 Table 5.8 – RS-232/RS-485 Converter (P/N 61-825-1032-4) RS-232 Connector 46 Table 5.9 – RS-232/RS-485 Converter (P/N 61-825-1032-4) RS-485 Connector 46 Table 5.10 – RS-232/RS-485 Converter (P/N 61-825-1032-4) Jumpers Table 6.1 – Sample Tag Table for Direct-to-Host applications 51

1 47

Introduction

1.1 Premise

This Programming Guide was written for the user who is connecting Flowserve Limitorque DDC-100 Network-compatible valve actuators directly to a control system Host computer. These guidelines provide the information that is necessary to control and monitor the valve actuators through a serial data communications network.

Your safety and satisfaction are very important to Flowserve. Please follow all instructions carefully and pay special attention to safety.

1.2 Emphasis

The following methods will be used to emphasize text throughout this manual:

WARNING: Refers to personal safety. This alerts the reader to potential danger or harm.

Failure to follow the advice in warning notices could result in personal injury or death.

CAUTION: Directs attention to general precautions, which, if not followed, could result in

personal injury and/or equipment damage.

NOTE: Highlights information critical to the understanding or use of these products.

Bold text highlights other important information that is critical to system components.

CAPITALIZED text stresses attention to the details of the procedure.

Underlined text emphasizes crucial words in sentences that could be misunderstood if the word is not recognized.

The purpose of these emphasized blocks of text is to alert the reader to possible hazards associated with the equipment and the precautions that can be taken to reduce the risk of personal injury and damage to the equipment.

Read and become familiar with the material in these guidelines before attempting installation, operation, or maintenance of the equipment. Failure to observe precautions could result in serious bodily injury, damage to the equipment, or operational difﬁculty.

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1.3 Audience

These guidelines were written to help you successfully connect Limitorque valve actuators directly to a control system Host computer. You do not have to be an expert in electronics or digital controls to utilize this manual. However, this manual assumes that you have a working understanding of valve actuators and a fundamental understanding of control system programming.

The following manuals should be available before attempting to connect the valve actuators to the control system:

1) Accutronix Installation and Operation for MX-DDC Field Unit Manual

Bulletin LMAIM1329

2) DDC-100 UEC Field Unit (Modbus®) Installation and Operation Manual

Bulletin LMAIM4029

3) DDC-100 UEC Field Unit Wiring and Startup Guidelines

Bulletin LMAIM4022

4) DDC-100 UEC Field Unit Installation and Commissioning Manual

Bulletin LMAIM4030

5) Modicon Modbus Protocol Reference Guide PI-MODBUS-300 Rev. G

available from Modicon

6) Valve actuator installation manual for the speciﬁc model(s) to be installed.

An understanding of valve actuators and digital control systems is beneﬁcial to all system users. Flowserve assistance and training is available to help you operate your system at top efﬁciency. It is recommended that you read this entire manual before attempting to install the valve actuators in your control system.

Direct-to-Host Valve

In this document, Direct-to-Host valve control is deﬁned as the use of a customer-supplied (possibly pre-existing) Host control system (PLC, DCS, PC, etc.) to directly control the actuation of valves that are equipped with DDC-100 Network-compatible ﬁeld units. The ﬁeld units are microprocessor-based devices that can communicate with the Host and respond to Host commands for valve motion and status. The DDC-100 Network uses the EIA RS-485 standard for the physical layer and the A.E.G. Modicon Modbus protocol for the command structure.

The Direct-to-Host solution to valve actuation systems provides distinct advantages for many users. These beneﬁts range from maximizing system design ﬂexibility to utilizing existing plant equipment for valve actuator control. The customer can emphasize selecting the best equipment and software that closely matches the application’s requirements. This solution allows the user to add valve control while avoiding the need to incorporate new control equipment into the facility. Direct-to-Host functionality is accomplished through the use of open architecture control and communications in the valve actuator controls that economically accommodate widely available interfaces for existing SCADA, PLC, or personal computers.

Control

2.1 Advantages of Direct-to-Host Control

• Freedom to design a valve actuator system to interface directly with customer-preferred supervisory equipment with open-market availability and off-the-shelf components.

• Maximizes valve actuator system exibility by utilizing the industry standard protocol of Modbus,

complemented with the EIA RS-485 electrical standard.

• Increases control room equipment utilization while incorporating a cost savings to the customer

through the elimination of unnecessary hardware.

• Supports the use of control system components familiar to the user and eliminates the requirement to learn third-party interfaces.

• Strengthens control system architecture with components readily available on the open market.

• Encourages parts replacement and support programs favorable to the user.

• Promotes direct downloading of valve actuator data to the supervisory control system without

intervening proprietary hardware or protocols.

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• Provides a safe and reliable communications path between the supervisory control system and

valve actuator network. This eliminates an unnecessary single point of failure that would exist if the valve control network required a gateway device.

• Enhances the operational relationship between the customer and the customer’s preferred system

integrator.

2.2 Deliverables for Successful Direct-to-Host Implementations

Each Direct-to-Host installation requires coordination to ensure that every supplier understands their deliverable responsibilities. When suppliers understand particular obligations and perform the tasks in an orderly and timely fashion, the DDC-100 Network installation process will progress very smoothly. Appendix A outlines a “typical” chart detailing areas of responsibility or supplier deliverables for installing a DDC-100 system. This appendix is a guideline and may vary from project to project.

Field Unit

Monitoring and Control

Flowserve Limitorque valve actuators that are DDC-100 Network compatible can be controlled and monitored by sending queries and receiving responses over a serial data network. The DDC-100 Network uses the non-proprietary Modbus message protocol and EIA RS-485 standard for the physical communication link.

Table 3.1 – Field Unit Communication Parameters

Parameter Options Default

Message Framing RTU, ASCII RTU

Baud Rate 1200, 2400, 4800, 9600, 19,200 9600

Data Bits 8 8

Stop Bits 1 1

Parity None None

Error Checking CRC-16 (RTU), LRC (ASCII) CRC-16 (RTU)

Field Unit Address Range 1–250 Conﬁgurable Conﬁgurable

3.1 Use of Coils and Registers for Monitoring and Control

The material in this section is a brief tutorial and general discussion of the use of Modbus queries and responses to control valve actuators. The detailed discussion of the commands will be given in Section 3.2.

The Modbus communications protocol allows for working with two types of information—coils (or bits) and registers (or 16-bit words). Coils are either ON (1) or OFF (0) and are used in direct relation to relays (that have coils). For example, in a typical actuator, Coil 1 is energized to CLOSE the actuator and Coil 2 is energized to OPEN the actuator. Register information is used for control functions that do not involve coils. An example would be to write a command value to energize the open or close coil or move the actuator to a position of 0 to 100% of open.

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Queries are used to send requests from the Modbus master (Host) to the Modbus slave (DDC-100 Field Unit), and the slave must respond with an appropriate response or an error message.

The Modbus function codes that are supported in the DDC-100 Network are a subset of the complete Modbus function codes and are listed below:

01 Read Coil Status Reads the ON/OFF status of discrete outputs (coils) in the ﬁeld units.

02 Read Input Status Reads the ON/OFF status of discrete inputs in the ﬁeld units.

03 Read Holding Registers Reads the binary contents of holding registers in the ﬁeld units.

04 Read Input Registers Reads the binary contents of the input registers in the ﬁeld units.

05 Force Single Coil Forces a single coil to either the ON or OFF state.

06 Preset Single Register Presets a value into a single-holding register.

08 Diagnostics Provides communication tests and checks for internal error conditions in the

ﬁeld units.

Table 3.2 – Modbus Function Codes Supported

Function

Code

Note: MX-DDC does not support Modbus function code 02.

Name

01 Read Coil Status Bit 0,000 - 9,999

02 Read Input Status Bit 10,000 - 19,999

03 Read Holding Register Register 40,000 - 49,999

04 Read Input Register Register 30,000 - 39,999

05 Force Single Coil Bit 0,000 - 9,999

06 Preset Single Register Register 40,000 - 49,999

08 Diagnostics N/A N/A

15 Force Multiple Coils Bit 0,000 - 9,999

16 Preset Multiple Registers Register 40,000 - 49,999

Modbus function codes 15 and 16 are supported in: UEC-3-DDC Modbus Firmware 2.00 and greater MX-DDC Firmware 02/01.00 and greater

Bit/Register Addressing

Extended Addressing Range

15 Force Multiple Coils Forces multiple coils to either the ON or OFF state.

16 Preset Multiple Registers Presets a value into multiple holding registers.

NOTE: All data in Modbus messages are referenced to zero. The ﬁrst occurrence of a data item is addressed as item number zero. This includes Coils, Inputs, and Registers. For example, coils 1-8 would be addressed as 0-7, inputs 1-16 would be addressed as 0-15, and registers 1-16 would be addressed as 0-15.

3.2 Modbus

The Modbus protocol was developed by A.E.G. Modicon for communicating to various networked devices. The relationship between these devices and a central controller is called a master-slave relationship in which the master (Host device) initiates all communications. The slave devices (ﬁeld units in the actuators) respond to the queries from the master. Modbus only permits one master to communicate at any given time (simultaneous communication is prohibited) for assuring process control integrity.

The controlling device (master) must conform to the Modbus protocol as deﬁned in the Modicon Modbus Protocol Reference Guide PI-MODBUS-300 Rev. G and support Modbus function codes 01 through 06, 08, 15 and 16. These function codes are a subset of the complete protocol and are deﬁned in Table 3.2.

The choice of which query to use in a particular situation can signiﬁcantly affect the efﬁciency of the network. As an example, consider the situation where the Host requires the status of the coils, the status of the digital inputs, the status of the faults, and the status of the timers and analog channels. This information can be obtained by using the 01 - Read Coil Status query, the 02 - Read Input Status query, and 04 - Read Input Register query. To obtain this information, the Host would have to send three separate queries, and the ﬁeld unit would have to respond to each query separately. A more efﬁcient way to accomplish this same request for information would be through the use of the 03 - Read Holding Register query. The Host would issue the 03 query (specifying the registers to read), and the ﬁeld unit would respond with one response that would contain all of the requested information. The latter approach would generate considerably less network trafﬁc than the former approach, improving network capacity and response times.

In the strict sense, all transmissions from the Modbus master are called commands. In this manual, a request for information, however, may be referred to as a query. Usually the term query will only be used in conjunction with function codes (01), (02), (03), (04), and (08), which typically request data. Commands are used in conjunction with function codes (05), (06), (15) and (16), which typically initiate ﬁeld unit action.

Examples

• The coil known as “coil 1” in the eld unit is addressed as coil 0000 in the data address eld of a

Modbus message.

• Digital input 129 decimal is addressed as digital input 0080 hex (128 decimal).

• Holding register 40001 is addressed as register 0000 in the data address eld of the message.

The function code ﬁeld already speciﬁes “holding register” operation. Therefore the reference “4XXXX” is implicit.

• Holding register 40009 is addressed as register 0008 hex (8 decimal).

3.2.1 Modbus Function Code 01 (Read Coil Status)

This function code is used to read the coil status in the DDC-100 Field Unit. There are nine coils available to be read on DDC-100 Field Units as shown in Table 3.3. For the MX/DDC or UEC-3-DDC Field Unit, Coil 1 indicates CLOSE contactor and is interlocked with Coil 2, Coil 2 indicates OPEN contactor and is interlocked with Coil 1. When the I/O Module is used in non-MOV (motor-operated valve) mode, relays 1 through 6 or coils 3 through 8 are available for user conﬁguration.

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Table 3.3 – DDC-100 Coil Assignments, Modbus Function Code 01 Usage for Digital Outputs

Coil

Number

1 00 Close / Stop Close / Stop Close / Stop Do Not Use

2 01 Open / Stop Open / Stop Close / Stop Do Not Use

3 02 AS-1 Lockout or Relay #3 Lockout or Relay #3 Relay #3

4 03 AS-2 Do Not Use Relay #4 Relay #4

5 04 AS-3 Do Not Use Relay #5 Relay #5

6 05 AS-4 Relay #6 Relay #6 Relay #6

7 06 AR-1 (Opt) Do Not Use Do Not Use Relay #21

8 07 AR-2 (Opt) Do Not Use Do Not Use Relay #12

9 08 AR-3 (Opt) Do Not Use Do Not Use Do Not Use

Note 1: Relay #2 is physical Relay K2.

Note 2: Relay #1 is physical Relay K1.

Bit

Number

MX/DDC UEC-3-DDC DDC-100 Clamshell I/O Module

Example

Poll ﬁeld unit number 3 for 8 coils starting at coil 1.

Query 0301000000083C2E

Response 03010118503A

Message Breakdown

Query Response

03 Slave (Field Unit) Address 03

01 Function 01 Function

00 Starting Address Hi 01 Byte Count

00 Starting Address Lo 18 1 Data (Coils 8 - 1)

00 No. of Points Hi 503A Error Check (CRC)

08 No. of Points Lo

3C2E Error Check (CRC)

Note 1: 18h equals 00011000 or coils 4 and 5 are ON.

Slave (Field Unit) Address

3.2.2 Modbus Function Code 02 (Read Input Status)

This function code is used to read the discrete input status bits in the DDC-100 Field Unit. The use of this function code will provide the user with the input status bits that are used to develop holding registers 9 through 13. The status bit inputs are contained in locations 10129-10208 for each DDC-100 Field Unit and are deﬁned in Table 3.4.

Table 3.4 – Status Bit Deﬁnitions

Bit Number

129 128 Opened Not Used

130 129 Closed Not Used

131 130 Stopped Not Used

132 131 Opening Not Used

133 132 Closing Not Used

134 133 Valve jammed Not Used

135 134 Actuator switched to local mode Not Used

136 135 Combined fault Not Used

Modbus

Bit

Address

UEC-3-DDC and DDC-100 Clamshell I/O Module

Table 3.4 – Status Bit Deﬁnitions (continued)

Bit Number

137 136 Over-temperature fault Not Used

138 137 Actuator failing to de-energize Not Used

139 138 Channel A fault Channel A fault

140 139 Channel B fault Channel B fault

141 140 Open torque switch fault Not Used

142 141 Close torque switch fault Not Used

143 142 Valve operated manually fault Not Used

144 143 Phase error Not Used

145 144

146 145

147 146

148 147

149 148

150 149

151 150

152 151

153 152

154 153

155 154

156 155 Local emergency shutdown is active Not Used

157 156

158 157 Wrong rotation Not Used

159 158 Opening in local mode Not Used

160 159 Closing in local mode Not Used

161 160 Close contactor (interlocked) Not Used

162 161 Open contactor (interlocked) Not Used

163 162 Lockout or user, Relay 3 Relay 3

164 163

165 164

166 165 User, Relay 6 Relay 6

167 166 Close contactor (non-interlocked) Relay 2 (K2)

168 167 Open contactor (non-interlocked) Relay 1 (K1)

169 168 Field unit software vs. ID Field unit software vs. ID

170 169 Field unit software vs. ID Field unit software vs. ID

171-176 170-175 Field unit software vs. ID Field unit software vs. ID

177 176 Remote switch User Input 8

178 177 Thermal overload User Input 9

Modbus

Bit

Address

UEC-3-DDC and DDC-100 Clamshell I/O Module

Input “open verify” is not active after open command is initiated

Input “close verify” is not active after close command is initiated

Input “open verify” is active after open command is de-energized

Input “close verify” is active after close command is de-energized

“Ph_det” (Phase Detect) input is active. One or more phases is missing

“Ph_seq” (Phase Sequence) input is active. Reverse phase sequence is occurring

Valve manually moved from mid-travel to open

Valve manually moved from open to mid-travel

Valve manually moved from mid-travel to close

Valve manually moved from close to mid-travel

Network emergency shutdown (ESD) is active

Field unit microprocessor has reset since the last poll

Local pushbutton switch LED (UEC-3) Relay 4 (Clamshell)

Local pushbutton switch LED (UEC-3) Relay 5 (Clamshell)

Not Used

Relay 4

Relay 5

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Table 3.4 – Status Bit Deﬁnitions (continued)

Bit Number

179 178 Open torque switch User Input 10

180 179 Open limit switch User Input 11

181 180 Close torque switch User Input 12

182 181 Close limit switch User Input 13

183 182 Aux. Open Input User Input 14

184 183 Aux. Close Input User Input 15

185 184 User Input 0 User Input 0

186 185 User Input 1 User Input 1

187 186 User Input 2 User Input 2

188 187 User Input 3 User Input 3

189 188 User Input 4 User Input 4

190 189 User Input 5 User Input 5

191 190 Input 6 User Input 6

192 191 Input 7 User Input 7

193 192 Analog Input 1 lost Analog Input 1 lost

194 193 Analog Input 2 lost Analog Input 2 lost

195 194 Analog Input 3 lost Analog Input 3 lost

196 195 Analog Input 4 lost Analog Input 4 lost

197 196 Network Channels A/B timed out Network Channels A/B timed out

198 197 Reserved Reserved

199 198 Reserved Reserved

200 199 Reserved Reserved

201 200 Reserved Reserved

202 201 Reserved Reserved

203 202 Reserved Reserved

204 203 Reserved Reserved

205 204 Lost Phase Input User Input 18

206 205 Phase Reverse Input User Input 19

207 206 Input 8 User Input 16

208 207 Input 9 User Input 17

Modbus

Bit

Address

UEC-3-DDC and DDC-100 Clamshell I/O Module

Example

Poll ﬁeld unit number 22 for 16 inputs starting at input 129 with the actuator opening.

Query 1602008000107B09

Response 1602020108CDED

Message Breakdown

Query Response

16 Slave (Field Unit) Address 16 Slave (Field Unit) Address

02 Function 02 Function

00 Starting Address Hi 02 Byte Count

80 Starting Address Lo 01

00 No. of Points Hi 08

10 No. of Points Lo CDED Error Check (CRC)

7B09 Error Check (CRC)

Note 1: 01h equals 0000 0001 (actuator open input bit is ON).

Note 2: 08h equals 0000 1000 (actuator Channel B Fail bit is ON).

Data (Inputs 10136 - 10129)

Data (Inputs 10144 - 10137)

3.2.3 Modbus Function Code 03 (Read Holding Register)

This function code is used to read the binary contents of holding registers in the DDC-100 Field Unit. This function code is typically used during the network polling cycle. A network poll should consist of ﬁeld unit registers 9 (Status) and 10 (Fault) as a minimum. Holding register 8 should also be polled when the actuator is conﬁgured for the analog feedback option or position control. See Table 3.5 for a complete listing of the holding registers.

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Table 3.5 – Field Unit Register Deﬁnitions

1 Command

2 Argument

3 Analog Output

4 Analog Output

5 Analog Input Main Power Value (Volts) Analog Input 4

6 Analog Input

7 Analog Input

8 Position

Status Register (Field Units as

MOV - MotorOperated Valve)

Status Register I/O Module only

(Non-Valve Service)

Registers 1 and 2 are write-only registers used for Modbus Function Code 06

APT Scaled Output Value (Default 0-100)

ATT Scaled Output Value1 (Default 0-100)

Analog Input 1 (Default 0-100) User 4-20 mA Input (Heavy Smoothing)

Analog Input 2 (Default 0-100) User 4-20 mA Input

Valve Position, Scaled Value (Default 0-100) (0-100, 2-255, 0-4095)2

16 Bits of Field Unit Status 16 Bits of Field Unit Status

Bit 0 Opened Bit 0 Opened

Bit 1 Closed Bit 1 Closed

Bit 2 Stopped Bit 2 Stopped

Bit 3 Opening Bit 3 Opening

Bit 4 Closing Bit 4 Closing

Bit 5 Valve jammed Bit 5 Valve jammed

Bit 6 Actuator switched to local

mode1

Bit 7 Combined fault3 Bit 7 Combined fault3

Bit 8 Over-temperature fault Bit 8 Over-temperature fault

Bit 9 Future Implementation

Bit 10 Network Channel A fault4 Bit 10 Network Channel A fault

Bit 11 Network Channel B fault4 Bit 11 Network Channel B fault

Bit 12 Open torque switch fault Bit 12 Open torque switch fault

Bit 13 Close torque switch fault Bit 13 Close torque switch fault

Bit 14 Valve-operated manually

fault

Bit 15 Phase error Bit 15 Phase error

N/A

Registers 1 and 2 are write-only registers used for Modbus Function Code 06

N/A

Average Torque (version 2.00 and greater)

Analog Input 3

Analog Input 2

Valve Position, Scaled Value (Default 0-100) OR Analog Input 1

Bit 6 Actuator switched to local

Bit 9 Actuator failing to de-ener-

Bit 14 Valve-operated manually

16 Bits of Field Unit Status

Bits 0-9 Not Used

Bit 10 Network Channel A fault

Bit 11 Network Channel B Fault

Bits 12-15 Not Used

mode

gize

fault

Table 3.5 – Field Unit Register Deﬁnitions (continued)

Number

16 Bits of Field Status 16 Bits of Field Status

Bits 0-3 Not Used

Bit 4 One or more phases are

missing

Bit 5 Reverse phase sequence is

occurring

Bits 6-9 Not Used

Bit 10 Network emergency

shutdown is active

Bit 11 Local PB emergency

shutdown is active

Bit 12 MX microprocessor has

reset since the last poll

Bit 13 Local Stop

Bit 14 Opening in local mode

Bit 15 Closing in local mode

Fault Register (Not Used for I/O Module)

Bit 0 Input “open verify” is not

active after open command is initiated

Bit 1 Input “close verify” is not

active after close command is initiated

Bit 2 Input “open verify” is active

after open command is de-energized

Bit 3 Input “close verify” is active

after close command is de-energized

Bit 4 “Ph_det” input is active. One

or more phases are missing

Bit 5 “Ph_seq” input is active.

Reverse phase sequence is occurring

Bit 6 Valve manually moved from

mid-travel to open

Bit 7 Valve manually moved from

open to mid-travel

Bit 8 Valve manually moved from

mid-travel to close

Bit 9 Valve manually moved from

close to mid-travel

Bit 10 Network emergency

shutdown is active

Bit 11 Local emergency shutdown

is active

Bit 12 Field Unit microprocessor

has reset since the last poll

Bit 13 Wrong rotation

Bit 14 Opening in local mode

Bit 15 Closing in local mode

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Table 3.5 – Field Unit Register Deﬁnitions (continued)

Value of 16 Digital Outputs Value of 16 Digital Outputs

Bit 0 Close contactor (interlocked)

Bit 1 Open contactor (interlocked)

Bit 2 AS-1 Bit 2 Lockout or User Relay 3

Bit 3 AS-2

11 Digital Outputs

12 Digital Inputs 1

Bit 4 AS-3

Bit 5 AS-4

Bit 6 AR-1 (Opt)

Bit 7 AR-2 (Opt)

Bit 8 AR-3 (Opt) Bits 8-15 Field Unit Software vs. ID

Bit 9 Network Relay

Bits 10-15 Not Used

Value of 16 Digital Inputs Value of 16 Digital Inputs

Bit 0 Remote Switch

Bit 1 Thermal Overload

Bit 2 Open Torque Switch

Bit 3 Open Limit Switch

Bit 4 Close Torque Switch

Bit 5 Close Limit Switch

Bit 6 Not Used

Bit 7 Not Used

Bit 8 User Input 0, terminal 21

Bit 9 User Input 1, terminal 10

Bit 10 User Input 2, terminal 9

Bit 11 User Input 3, terminal 6

Bit 12 User Input 4, terminal 7

Bit 13 User Input 5, terminal 5

Bit 14 Opt User Input 6,

terminal 23

Bit 15 Opt User Input 7,

terminal 24

Bit 0 Close contactor (interlocked),

I/O Module as MOV (MotorOperated Valve)

Bit 1 Open contactor (interlocked),

I/O Module as MOV

Bit 3 UEC-3-DDC Local push-

button switch LED, Relay 4 Clamshell and I/O Module

Bit 4 UEC-3-DDC Local push-

button switch LED, Relay 5 Clamshell and I/O Module

Bit 5 Relay 6 Clamshell and I/O

Module

Bit 6 Relay 2 (K2), I/O Module

(non-interlocked)

Bit 7 Relay 1 (K1), I/O Module

(non-interlocked)

Bit 0 Remote Switch, I/O Module

Input 8

Bit 1 Thermal Overload, I/O

Module Input 9

Bit 2 Open Torque Switch, I/O

Module Input 10

Bit 3 Open Limit Switch, I/O

Module Input 11

Bit 4 Close Torque Switch, I/O

Module Input 12

Bit 5 Close Limit Switch, I/O

Module Input 13

Bit 6 Aux. Open Input, I/O Module

Input 14

Bit 7 Aux. Close Input, I/O Module

Input 15

Bit 8 User Input 0, I/O Module

Input 0

Bit 9 User Input 1, I/O Module

Input 1

Bit 10 User Input 2, I/O Module

Input 2

Bit 11 User Input 3, I/O Module

Input 3

Bit 12 User Input 4, I/O Module

Input 4

Bit 13 User Input 5, I/O Module

Input 5

Bit 14 Input 6, I/O Module Input 6

Bit 15 Input 7, I/O Module Input 7

Table 3.5 – Field Unit Register Deﬁnitions (continued)

Number

Value of 16 Digital Inputs Value of 16 Digital Inputs

Bit 0 Not Used Bit 0 Analog Input 1 lost

Bit 1 Not Used Bit 1 Analog Input 2 lost

Bit 2 Analog input 1 lost Bit 2 Analog Input 3 lost

Bit 3 Analog input 2 lost Bit 3 Analog Input 4 lost

Bit 4 Network Channels A/B

timed out

Bit 5 Not Used Bit 5 Reserved

Bit 6 DDC board present Bit 6 Reserved

Bit 7 I/O option board present Bit 7 Reserved

13 Digital Inputs 2

Timers and

Analog Channels

Bit 8 Not Used Bit 8 Reserved

Bit 9 Not Used Bit 9 Reserved

Bit 10 Not Used Bit 10 Reserved

Bit 11 Not Used Bit 11 Reserved

Bit 12 Phase lost

Bit 13 Phase reverse

Bit 14 Opt User Input 8,

terminal 25

Bit 15 Not Used

Bit 15 Input 9, I/O Module Input 17

Bits 0-15 – Not Used

Bit 4 Network Channels A/B

timed out

Bit 12 Phase lost input, I/O Module

Input 18

Bit 13 Phase reverse input, I/O

Module Input 19

Bit 14 Input 8, I/O Module Input 16

Value of 16 Bits

Bit 0 Analog Channel 1 Low

Bit 1 Analog Channel 2 Low

Bit 2 Analog Channel 3 Low

Bit 3 Analog Channel 4 Low

Bit 4 Analog Channel 1 High

Bit 5 Analog Channel 2 High

Bit 6 Analog Channel 3 High

Bit 7 Analog Channel 4 High

Bit 8 Open reversal time-out

Bit 9 Close reversal time-out

Bit 10 Jammed valve time-out

Bit 11 Network Channel A time-out

Bit 12 Network Channel B time-out

Bit 13 User 1 time-out

Bit 14 User 2 time-out

Bit 15 User 3 time-out

14 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 15

Table 3.5 – Field Unit Register Deﬁnitions (continued)

24-44 Reserved Special Applications Only Special Applications Only

45-47 Not Named Special Applications Only Special Applications Only

Value of 16 Bits

Bit 0 User Fault 0

Bit 1 User Fault 1

Bit 2 User Fault 2

Bit 3 User Fault 3

15 User Faults Bits 1-15 – Not Used

16 Current State Bits 0-15 – Not Used

Field Unit

Holding Register

Field Unit

Holding Register

Field Unit

Holding Register

Field Unit

Holding Register

Field Unit

Holding Register

Field Unit

Holding Register

Field Unit

Holding Register

TP_START_

POSITION

TP_STOP_POSI-

TION

50 TP_SAMPLE Special Applications Only Special Applications Only

51 TP_MID_T_HIGH Special Applications Only Special Applications Only

52 TP_MID_T_POS Special Applications Only Special Applications Only

Special Applications Only Special Applications Only

Bit 4 User Fault 4

Bit 5 User Fault 5

Bit 6 User Fault 6

Bit 7 User Fault 7

Bit 8 User Fault 8

Bit 9 User Fault 9

Bits 10-15 Reserved

Value of 16 Bits

Bit 0 Waiting to Open

Bit 1 Waiting to Close

Bit 2 Running Backward

Bit 3 Invalid Conﬁguration

Bit 4 Reverse Switches

Bit 5 OK to Modulate

Bits 6-15 Reserved

Table 3.5 – Field Unit Register Deﬁnitions (continued)

Number

Note 1: Torque will be expressed proportionally as a reference only from 40-100% inclusive. Initial indication may read 0% until torque exceeds 40% minimum.

Note 2: Default value is scaled 0-100 of span. Changes made to “Scale Analog” affect Analog registers (3, 4, 6, 7, 8) and “move-to” commands.

Note 3: Combined Fault bit is a value of 1 or true when bit 5 or 8 or 9 or 15 or (bits 10 and 11) is a value of 1 or true.

Note 4: Channel A is physical connection A1. Channel B is physical connection A2.

MX/DDC actuators shipped prior to 2nd QTR, 1999, have the following deﬁnition for Register 9 bit 6. When this bit has a value of 1 or true, the actuator selector switch is in LOCAL mode. This bit does not indicate STOP or REMOTE. The actuator selector switch in REMOTE (available for network control) is indicated by Register 12 bit 00 having a value of 1 or true. Register 9 bit 6 value 0 (zero) or false AND Register 12 bit 00 value 0 (zero) or false indicates selector switch is in the STOP position.

MX/DDC actuators shipped after 2nd QTR, 1999, have the following deﬁnition of Register 9 bit 6. When this bit has a value of 1 or true, the actuator is in LOCAL or STOP (unavailable for network control). The actuator selector switch in REMOTE (available for network control) is indicated by Register 12 bit 00 having value of 1 or true.

IMPORTANT: Verify Host program when installing an MX/DDC actuator shipped after 2nd QTR, 1999, on a network commissioned before 2nd QTR, 1999, for indication of selector switch values. Proper selector switch indication at the Host will ensure safe conditions at the facility.

TP_MID_T_AV_

VAL

54 TP_STOP_VAL Special Applications Only Special Applications Only

TP_BEFORE

MID_T_HIGH_

TP_AFTER

MID_T_HIGH

Special Applications Only Special Applications Only

Example

Poll ﬁeld unit number 125 for 3 registers starting at register 8 with the actuator stopped between the limits and in local mode.

Query 7D0300070003BFF6

Response 7D0306003D084400003E07

Message Breakdown

Query Response

7D Slave (Field Unit) Address 7D Slave (Field Unit) Address

03 Function 03 Function

00 Starting Address Hi 06 Byte Count

07 Starting Address Lo 00 Data Hi (Register 40008)

00 No. of Points Hi 3D

03 No. of Points Lo 08 Data Hi (Register 40009)

BFF6 Error Check (CRC) 44

Note 1: 003Dh equals 61 Decimal (actuator Analog Input 1 in percent format).

Note 2: 0844h equals 2116 Decimal or 0000 1000 0100 0100 Binary (actuator stopped between limits, local mode, and Channel B Fail bit is ON).

00 Data Hi (Register 40010)

00 Data Lo (Register 40010)

3E07 Error Check (CRC)

Data Lo (Register 40008)

Data Lo (Register 40009)

16 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 17

3.2.4 Modbus Function Code 04 (Read Input Register)

This function code is used to read the binary contents of input registers in the DDC-100 Field Unit. The typical use of this function code is to read the analog input registers. If the ﬁeld unit is conﬁgured for scaled analog data, the register information will be returned as a percent from 0 to 100 (see NOTE below). The ﬁrst analog input register (Analog 4) will start at register 30005 through (Analog 1) Input Register 30008.

This function code may also be used to read the information available in registers 9 through 16.

NOTE: Limitorque ﬁeld units can be conﬁgured to report analog data in several formats. See the appropriate ﬁeld unit manual for details.

Example

Poll ﬁeld unit number 70 for 4 registers starting at register 5 (Analog Input Registers 1-4).

(This example assumes that the ﬁeld unit is conﬁgured for scaled analog data.)

Table 3.6 – DDC-100 Coil Assignments Modbus Function Code 05 Usage for Digital Outputs

Coil

Number

1 00 Close / Stop Close / Stop Close / Stop Do Not Use

2 01 Open / Stop Open / Stop Open / Stop Do Not Use

3 02 AS-1 Lockout or Relay #3 Lockout or Relay #3 Relay #3

4 03 AS-2 Do Not Use Relay #4 Relay #4

5 04 AS-3 Do Not Use Relay #5 Relay #5

6 05 AS-4 Relay #6 Relay #6 Relay #6

7 06 AR-1 (Opt) Do Not Use Do Not Use Relay #21

8 07 AR-2 (Opt) Do Not Use Do Not Use Relay #12

9 08 AR-3 (Opt) Do Not Use Do Not Use Do Not Use

Note 1: Relay #2 is physical Relay K2.

Note 2: Relay #1 is physical Relay K1.

Bit

Number

MX/DDC UEC-3-DDC DDC-100 Clamshell I/O Module

Query 460400040004BF7F

Response 460408FFFFFFFF002B001EDBA8

Message Breakdown

Query Response

46 Slave (Field Unit) Address 46 Slave (Field Unit) Address

04 Function 04 Function

00 Starting Address Hi 08 Byte Count

04 Starting Address Lo FF Data Hi (Register 40005)

00 No. of Points Hi FF

04 No. of Points Lo FF Data Hi (Register 40006)

BF7F Error Check (CRC) FF

00 Data Hi (Register 40007)

00 Data Hi (Register 40008)

DBA8 Error Check (CRC)

Note 1: FFFFh equals 65535 Decimal (actuator Analog Input 4 value).

Note 2: FFFFh equals 65535 Decimal (actuator Analog Input 3 value).

Note 3: 002Bh equals 43 Decimal (actuator Analog Input 2 value).

Note 4: 001Eh equals 30 Decimal (actuator Analog Input 1 in percent format).

Data Lo (Register 40005)

Data Lo (Register 40006)

Data Lo (Register 40007)

Data Lo (Register 40008)

The normal response to the (05) command is an echo of the command.

Example of force coil command

Force coil 1 of ﬁeld unit 49 ON. This will CLOSE the valve controlled by ﬁeld unit 49.

Query 31050000FF0089CA

Response 31050000FF0089CA

Message Breakdown

Query Response

31 Slave (Field Unit) Address 31

05 Function 05 Function

00 Coil Address Hi 00 Coil Address Hi

001 Coil Address Lo 00 Coil Address Lo

FF Force Data Hi FF Force Data Hi

002 Force Data Lo 00 Force Data Lo

89CA Error Check (CRC) 89CA Error Check (CRC)

Note 1: 0000h equals Coil Address 00000001 (ﬁeld unit coil 1). 0001h equals Coil Address 00000010 (ﬁeld unit coil 2).

Note 2: FF00h requests the coil to be ON. (0000h requests the coil to be OFF)

Slave (Field Unit) Address

3.2.5 Modbus Function Code 05 (Force Single Coil)

This function code is used to force a single coil in the DDC-100 Field Unit. Forcing the individual coil either ON (1) or OFF (0) will energize or de-energize a coil (digital output) in the ﬁeld unit. Coil 1 in the ﬁeld unit closes the actuator and Coil 2 opens the actuator. If the actuator is opening or closing, changing the status of coil 1 or 2 from a value of 1 to 0 will stop the actuator (the coil will automatically be set to zero when the actuator reaches the full open or full close position).

Available digital outputs for DDC-100 Field Units are listed in Table 3.6. Force-coil commands should be issued only once for the desired ﬁeld unit control. Repeated issuance of an acknowledged command will degrade network performance.

3.2.6 Modbus Function Code 06 (Preset Single Register)

This function code is used to preset a single register in the ﬁeld unit. The function code is typically used to command the DDC-100 Field Unit by writing values to the 40001 and 40002 registers. A predetermined value may be used to open/stop/close the actuator, move the actuator to a preset position, activate/deactivate network ESD, reset the ﬁeld unit, etc.

The Modbus function code 06 is also used to command a throttling actuator to “move-to” a position of 0-100% of open. The ﬁeld unit will compare the new position value with the current position and open or close the valve to meet the new position requirement. This is a two-step command: the ﬁrst step is to write the desired position value to the ﬁeld unit register 40002, then write the value of 6656 to ﬁeld unit register 40001. This sequence of commands loads the desired position, then

NOTE: See Bulletin LMAIM1329, Accutronix Installation and Operation for MX-DDC Field Unit to

instructs the ﬁeld unit to execute the command.

conﬁgure AS and AR Relays for DDC control.

For UEC-3-DDC ﬁeld units containing Modbus Firmware 2.00 or greater and MX-DDC ﬁeld units containing Firmware 02/01.00 or greater, the “move-to” command may be executed with a one-step command.

18 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 19

Modbus function code 06 command values for controlling the DDC-100 Field Unit are given in Table

3.7. Each command should be issued only one time for the desired ﬁeld unit control. Repeated issuance of an acknowledged command will degrade network performance.

Example of Field Unit Command

Write the command to open an actuator (actuator open) to ﬁeld unit number 179. This corresponds to writing the value 256 into ﬁeld unit register 40001.

The normal response to the (06) command is an echo of the command.

NOTE:

1) Only use values listed in table 3.7 For ﬁeld unit register 40001.

2) Field Unit Register 40002 should only be used for “move-to” position input.

3) The Host MUST issue “move-to” commands in the proper sequence. Failure to issue this two-step command in the correct sequence will result in the ﬁeld unit waiting for the proper command sequence execution before performing the “move-to” function.

4) The “move-to” command should only be used with ﬁeld units that include the position control option.

5) Do not write to Field Unit Registers 5-16.

Table 3.7 – Modbus 06 Command and Field Unit Holding Register 40001

Host Commands to Field Unit Register 1

Null Command 0 Yes Yes Yes Yes

Open 256 Yes Yes Yes Do Not Use

Stop 512 Yes Yes Yes Do Not Use

Close 768 Yes Yes Ye s Do Not Use

Start Network ESD 1280 Yes Yes Ye s Do Not Use

Stop Network ESD 1536 Yes Yes Yes Do Not Use

Engage Relay #1 2304 Yes (AS-1) Do Not Use Do Not Use Yes, K21

Engage Relay #2 2560 Yes (AS-2) Do Not Use Do Not Use Yes, K12

Engage Relay #3 2816 Yes (AS-3) Yes Yes Yes

Engage Relay #4 3072 Yes (AS-4) Do Not Use Yes Ye s

Engage Relay #5 3328 Yes (AR-1) Do Not Use Yes Yes

Engage Relay #6 3584 Yes (AR-2) Yes Ye s Yes

Engage Relay #7 3840 Yes (AR-3) Do Not Use Do Not Use Do Not Use

Disengage Relay #1 4352 Yes (AS-1) Do Not Use Do Not Use Yes, K21

Disengage Relay #2 4608 Yes (AS-2) Do Not Use Do Not Use Yes, K12

Disengage Relay #3 4864 Yes (AS-3) Yes Yes Yes

Disengage Relay #4 5120 Yes (AS-4) Do Not Use Yes Ye s

Disengage Relay #5 5376 Yes (AR-1) Do Not Use Yes Yes

Disengage Relay #6 5632 Yes (AR-2) Ye s Yes Ye s

Disengage Relay #7 5888 Yes (AR-3) Do Not Use Do Not Use Do Not Use

Move-To (enable) 6656 Yes Yes Ye s Do Not Use

Note 1: Engage and disengage Relay #1 control physical Relay K2.

Note 2: Engage and disengage Relay #2 control physical Relay K1.

Do Not Use–This command is not intended for use in this conﬁguration.

Other registers may also be preset to control or change other functions but care must always be taken to properly change these values. An improper value written to a register can cause undesirable actions from the DDC-100 Field Unit.

NOTE: Null Command–The ﬁeld unit takes no action when this command is received. This command is typically used by a Host to reset the Host output register when required.

Value (dec.)

MX-DDC UEC-3-DDC DDC-100

Clamshell

I/O Module

Query: B306000001009388

Response: B306000001009388

Message Breakdown

Query Response

B3 Slave (Field Unit) Address B3

06 Function 06 Function

00 Register Address Hi 00 Register Address Hi

001 Register Address Lo 00 Register Address Lo

01 Force Data Hi 01 Preset Data Hi

002 Force Data Lo 00 Preset Data Lo

9388 Error Check (CRC) 9388 Error Check (CRC)

Note 1: 0000h equals Register Address 40001 (ﬁeld unit register 1, command register).

Note 2: 0100h requests the register to be preset with 256 Decimal (engage open contactor).

Slave (Field Unit) Address

Example of “Move-To” Command

Move an actuator at address 179 to 42% of open by ﬁrst writing the value of 42 to the ﬁeld unit 40002 register. After receiving a response from the ﬁeld unit, write the value of 6656 to the ﬁeld unit 40001 register. The actuator will then move to a position of 42% of open.

First Command Query: B3060001002A4207

Response: B3060001002A4207

First Command Message Breakdown

Query Response

B3 Slave (Field Unit) Address B3

06 Function 06 Function

00 Register Address Hi 00 Register Address Hi

011 Register Address Lo 01 Register Address Lo

00 Force Data Hi 00 Preset Data Hi

2A2 Force Data Lo 2A Preset Data Lo

4207 Error Check (CRC) 4207 Error Check (CRC)

Note 1: 001h equals Register Address 40002 (ﬁeld unit register 2, argument register).

Note 2: 002Ah equals 42.

Slave (Field Unit) Address

20 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 21

Second Command Query B30600001A009978

Response B30600001A009978

Second Command Message Breakdown

Query Response

B3 Slave (Field Unit) Address B3

06 Function 06 Function

00 Register Address Hi 00 Register Address Hi

1A Force Data Hi 1A Preset Data Hi

9978 Error Check (CRC) 9978 Error Check (CRC)

Note 1: 0000h equals Register Address 40001 (ﬁeld unit register 1, command register).

Note 2: 1A00h equals 6656.

Force Data Lo 00 Preset Data Lo

Slave (Field Unit) Address

Example of single register write “move-to” command

This command allows a Host to issue the “move-to” command with a single write utilizing the Modbus function code 06. Register 1 will be used to complete this command.

Message Breakdown

Query Response

01 Slave Address 01 Slave Address

06 Function 06 Function

00 Starting Address Hi 00 Starting Address Hi

00 Starting Address Lo 00 Starting Address Lo

4B Preset Data Hi 4B Preset Data Hi

32 Preset Data Lo 32 Preset Data Lo

3EEF Error Check (LRC or CRC) 3EEF Error Check (LRC or CRC)

3.2.7 Modbus Function Code 08 (Diagnostics)

This function code provides a series of tests for checking the communication system between the Host and ﬁeld units (slaves), or for checking various error conditions within the ﬁeld unit. This function code uses a two-byte subfunction code ﬁeld in the query to deﬁne the type of test to be performed. The ﬁeld unit echoes both the function code and subfunction code in a normal response. It does not affect the ﬁeld unit in any way. If this exchange is successful, then the communication is successful.

A listing of the supported diagnostic two-byte subfunction codes is given in Table 3.8.

Rules for utilizing this command:

• Field unit scaling must be congured for 0-100.

• To use the hexadecimal method of determining a single write “move-to” command, 0x4B is

always placed into the Hi Byte of Register 1.

• The desired position value is always placed into the Lo Byte of Register 1.

To move the actuator to a position of 50%, place the value 0x4B in the high byte and the value of 0x32 (50 decimal) into the low byte.

Example: Hex format: 0x4B32

To use the decimal method of determining a single write “move-to” command, add the desired position value to 19200.

Example: Desired position: 50%

19200 + 50 = 19250

Example of single write “move-to” command

Move an actuator at address 1 to 50% of open by writing the value of 19250 (0x4B32) to the ﬁeld unit 40001 register. The actuator will then move to a position of 50% open.

Example Query: 010600004B323EEF

Response: 010600004B323EEF

Example

Request a loopback (return query data) from the ﬁeld unit at network address 3.

Query 030800000000E1E9

Response 030800000000E1E9

Message Breakdown

Query Response

03 Slave (Field Unit) Address 03 Slave (Field Unit) Address

08 Function 08 Function

00 Subfunction Hi 00 Subfunction Hi

00 Subfunction Lo 00 Subfunction Lo

00 Data Hi 00 Data Hi

00 Data Lo 00 Data Lo

E1E9 Error Check (CRC) E1E9 Error Check (CRC)

Table 3.8 – Diagnostic Codes Supported by the DDC-100 Field Unit

Code Name

00 Return Query Data

01 Restart Communication Option

02 Return Diagnostic Register1

03 Change ASCII Input Delimiter

04 Force Listen-Only Mode

10 (0A Hex) Clear Counters and Diagnostics Register

11 (0B Hex) Return Bus Message Count

12 (0C Hex) Return Bus Communication Error Count

13 (0D Hex) Return Bus Exception Error Count

14 (0E Hex) Return Slave Message Count

Note 1: Contains DDC-100 Field Unit diagnostic information. For engineering use only.

22 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 23

3.2.8 Modbus Function Code 15 (Force Multiple Coils)

This function code allows the user to force multiple coils with a single command and uses the same coil assignments as the function code 05.

It should be noted that the coils are operated from the lowest coil number to the highest. Forcing coil 1 or 2 OFF (0) is considered a stop command, sending a 15 command to force two coils starting with coil 1, with coil 1 ON and coil 2 OFF, would result in the unit stopping, since coil 2 is forced OFF after coil 1 is forced ON.

To prevent inadvertent Stop commands from being issued, it is recommended to force one coil at a time.

Available digital outputs for DDC-100 Field Units are listed in Table 3.6. Force multiple coil commands should be issued only once for the desired ﬁeld unit control. Repeated issuance of an acknowledged command will degrade network performance.

NOTE: This function code is implemented in UEC-3-DDC Modbus Firmware 2.00 and greater and MX-DDC Firmware 02/01.00 and greater

Example of force coil command

Force coil 1 of ﬁeld unit 1 ON. This will CLOSE the valve controlled by ﬁeld unit 1.

Query: 010F000000010101EF57

Response: 010F00000001940B

Message Breakdown

Query Response

01 Slave Address 01 Slave Address

0F Function 0F Function

00 Coil Address Hi 00 Coil Address Hi

00 Coil Address Lo 00 Coil Address Lo

00 Quantity of Coils Hi 00 Quantity of Coils Hi

01 Quantity of Coils Lo 01 Quantity of Coils Lo

01 Byte Count 940B Error Check (LRC or CRC)

01 Force Data Lo

EF57 Error Check (LRC or CRC)

Note: 000000010101h equals Coil Address 00000001 (ﬁeld unit coil 1)

000100010101h equals Coil Address 00000010 (ﬁeld unit coil 2)

3.2.9 Modbus Function Code 16 (Preset Multiple Registers)

This function code is used to preset single or multiple registers in the ﬁeld unit and uses the same predetermined register values as the function code 06. This function code is typically used to command the DDC-100 Field Unit by writing values to the 40001 and/or 40002 registers.

Modbus function code 16 command values for controlling the DDC-100 Field Unit are given in Table

3.7. Each command should be issued only one time for the desired ﬁeld unit control. Repeated

issuance of an acknowledged command will degrade network performance.

Example of Field Unit Command

Write the command to open an actuator (actuator open) to ﬁeld unit number 1. This corresponds to writing the value 256 into ﬁeld unit register 40001.

Query: 011000000001020100A7C0

Response: 01100000000101C9

Message Breakdown

Query Response

01 Slave Address 01 Slave Address

10 Function 10 Function

00 Starting Address Hi 00 Starting Address Hi

00 Starting Address Lo 00 Starting Address Lo

00 Number of Registers Hi 00 Number of Registers Hi

01 Number of Registers Lo 01 Number of Registers Lo

02 Byte Count 01C9 Error Check (LRC or CRC)

01 Preset Data Hi

00 Preset Data Lo

A7C0 Error Check (LRC or CRC)

Example of “Move-To” Command

Move an actuator at address 1 to 50% of open by presetting registers 40001 with the value 6656, and register 40002 with the value 50 in a single write command. The actuator will receive this message and move to a position of 50% open.

Query: 011000000002041A0000327562

Response: 01100000000241C8

Message Breakdown

Query Response

01 Slave Address 01 Slave Address

10 Function 10 Function

00 Starting Address Hi 00 Starting Address Hi

00 Starting Address Lo 00 Starting Address Lo

00 No. of Registers Hi 00 No. of Registers Hi

02 No. of Registers Lo 02 No. of Registers Lo

04 Byte Count 41C8 Error Check (LRC or CRC)

1A Preset Data Hi

00 Preset Data Lo

00 Preset Data Hi

32 Preset Data Lo

7562 Error Check (LRC or CRC)

Note: The single register write “Move-to” command may also be used with the function code

16. This function code may also utilize the Single Register write “move-to” command.

The normal response returns the slave address, function code, starting address, and quantity of registers preset.

NOTE: This function code is implemented in UEC-3-DDC Modbus Firmware 2.00 and greater and MX-DDC Firmware 02/01.00 and greater.

24 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 25

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The DDC-100

The Flowserve Limitorque DDC-100 Network is a digital communications network based on non-proprietary hardware and protocols. This network is capable of maintaining up to 250 valve actuators or other devices over a simple shielded, twisted-pair connection. The network consists of a master (Host PLC, Host Computer, Limitorque Master Station, or some other Master-capable device) and a number (up to 250) of ﬁeld units. The EIA RS-485 standard is used for the physical interface between devices to provide reliable communications over long distances.

Two protocols are supported by Limitorque Field Units—Modbus® and BITBUS®. The protocol must be speciﬁed when the units are ordered; however, the protocol may be changed in the ﬁeld (requires new EPROM). The Modbus protocol was developed by AEG Modicon and the BITBUS protocol was developed by the Intel Corp. Modbus protocol is more widely used, has a simpler implementation, and satisﬁes most applications that are not extremely time-critical. Therefore, this document addresses only the Modbus protocol. BITBUS protocol information is available upon request.

Network

NOTE: The MX-DDC does not support Bitbus protocol.

The network cable connects the ﬁeld unit to the Host System. Belden 3074F, 3105A, and 9841 shielded, twisted-pair cable should be used. The use of other cables may result in a reduction of internodal distances or increased error rate. Other individually shielded, twisted-pair cables with electrical properties within 5% of the recommended Belden cables may be used but have not been performance-tested with the DDC-100 Network.

Belden 3074F Speciﬁcations

• Total cable length between repeaters or nodes with repeaters: up to 19.2 kbps: 5000' (1.52 km)

For loop mode, this is the total length between operating ﬁeld units. If a ﬁeld unit loses power, relays internal to the ﬁeld unit connect the A1 Channel to the A2 Channel, which effectively doubles the length of the cable (assuming a single ﬁeld unit fails). If you need to assure operation within speciﬁcations in the event of power failure to ﬁeld units, then this consideration must be added. Example: To assure operation within speciﬁcation when any two consecutive ﬁeld units lose power,

then the maximum length on cable up to 19.2 kbps: 5000' (1.52 km) per every four eld units.

26 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 27

Key Specs

• Resistance/1000 ft = 18 AWG (7x26)

6.92 ohms each conductor (13.84 ohms for the pair)

• Capacitance/ft = 14 pF (conductor-to-conductor)

• Capacitance/ft = 14 pF (conductor-to-shield)

Belden 3105A Speciﬁcations

• Total cable length between repeaters or nodes with repeaters: up to 19.2 kbps: 4500' (1.37 km)

then the maximum length on cable up to 19.2 kbps: 4500' (1.37 km) per every four eld units.

Key Specs

• Resistance/1000 ft = 22 AWG (7x30)

14.7 ohms each conductor (29.4 ohms for the pair)

• Capacitance/ft = 11.0 pF (conductor-to-conductor)

• Capacitance/ft = 20.0 pF (conductor-to-shield)

The optional channel, Channel B, is used in network topologies that feature dual redundant communication paths. Please contact Flowserve for further information about dual redundant communication paths with the DDC-100 Network.

4.1.1 Field Unit Network Bypass Relays

Every Limitorque DDC-100 Field Unit is equipped with a set of network bypass relays designed to isolate the individual ﬁeld unit from the network in the event of a ﬁeld unit power failure. These normally closed relays are energized on ﬁeld unit power-up allowing the network data transmissions to enter the ﬁeld unit repeater circuitry and UART (Universal Asynchronous Receive Transmit circuit). When the ﬁeld unit power is turned off, these relays close, shorting the signal through the ﬁeld unit network board so the signal may pass to the next ﬁeld unit. This isolates the powereddown ﬁeld unit from the network while allowing the remainder of the network to function normally.

Care must be taken in the design of the DDC-100 network cable routing. This is necessary so maintenance programs or other group power outage conditions do not add more physical cable distance between two functional ﬁeld units than the RS-485 electrical signal can support.

NOTE: The MX-DDC Field Unit will not energize the network bypass relays until the ﬁeld unit is fully operational and ready to communicate. UEC-3-DDC Field Units revision 1.57 and greater will “fast start” the UART, preventing network communication disruption during the ﬁeld unit reboot cycle.

4.1.2 Field Unit Repeater Circuits

Belden 9841 Speciﬁcations

• Total cable length between repeaters or nodes with repeaters: up to 19.2 kbps: 3500' (1 km)

Key Specs

• Resistance/1000 ft = 24 AWG (7x32)

24 ohms each conductor (48 ohms for the pair)

• Capacitance/ft = 12.8 pF (conductor-to-conductor)

• Capacitance/ft = 23 pF (conductor-to-shield)

4.1 Field Unit Network Communication Channels

Before proceeding with discussions of network polling, network error monitoring, and network control, it is necessary to explain some network terminology with respect to ﬁeld unit communication channels, ports, and hardware features.

All Limitorque DDC-100 Field Units are provided with a dual port network communication channel. This channel is designated Channel A and the ports are designated ports A1 and A2. Both ports are capable of bi-directional serial communications and comply with the EIA RS-485 standard.

In addition, some ﬁeld units can optionally be ordered or retroﬁtted with a second dual port network communication channel. This channel is designated Channel B and the ports are designated ports B1 and B2. Channel B is implemented by adding a Granddaughter Board and an additional Network Board to the standard ﬁeld unit (not available with MX-DDC).

Every Limitorque DDC-100 Field Unit communications channel contains a repeater circuit that recenters, reclocks, and ampliﬁes the incoming signal and sends it out the opposite port. The circuit is bi-directional, so it will repeat the received signals from port A1 out A2 or from port A2 out A1. When the optional Granddaughter Board (not available with the MX-DDC) is added, the repeater also recenters, reclocks, and ampliﬁes the incoming signal received from B1 out B2 or from B2 out B1. Although the circuit resends the entire message, there is less than a one-bit time delay before retransmission out the corresponding port.

4.2 Network Topologies

Three network topologies are commonly used and supported by Limitorque—redundant loop, single-ended loop (or half loop), and single-line multi-drop. The recommended cable types for all three topologies are Belden 3074F, Belden 3105A, or Belden 9841. Other individually shielded, twisted-pair cables with electrical properties within 5% of Belden 3074F, Belden 3105A, or Belden 9841 may be used but have not been performance-tested with the DDC-100 Network.

4.2.1 Redundant Loop

The redundant loop topology requires two serial communication ports on the Host device. Because each ﬁeld unit can be accessed by two ports, redundant access paths are supported. The connections from the serial ports to the ﬁeld units and between ﬁeld units are made with shielded, twisted-pair cable in a loop conﬁguration. This topology tolerates a single-line break or short while maintaining communications to all ﬁeld units. Figure 4.1 shows the redundant loop network topology.

With redundant loop topology, serial data is transmitted from Host port 1 through an RS-232 to RS-485 converter to port A1 of the ﬁrst ﬁeld unit. The ﬁeld unit passes the data that comes in port A1 out through port A2 to the next ﬁeld unit A1 port. Each subsequent ﬁeld unit receives data through its A1 port then passes the data out through its A2 port to the next ﬁeld unit. The looped communication continues in this manner until the last ﬁeld unit port A2 relays the serial data to port

28 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 29

2 on the Host. The Host is not required to act on the data received at the second port. Note that, because of the bi-directional nature of the serial ports, the direction of data ﬂow can be reversed. Communications can be initiated by port 2 of the Host to port A2 of the ﬁrst ﬁeld unit. This data is then transmitted out port A1 to port A2 of the next ﬁeld unit. The data then continues in this direction until it reaches port 1 of the Host. In either direction, the signal is regenerated in each ﬁeld unit to permit longer-distance communications with reduced noise sensitivity and improved reliability.

Figure 4.1 – DDC-100 Redundant Loop Network

Legend

MOV

- Motor-Operated Valve

- Data A1

- Data A1*

- Data A2

41 29

- Data A2*

D-M

- Data A1 (UEC-3-DDC)

- Data A1*(UEC-3-DDC)

D-M* D-S

- Data A2 (UEC-3-DDC)

- Data A2* (UEC-3-DDC)

D-S*

- Shield

N/C

- No Connection

Data terminal is positive with respect to data* terminal

MOV-2

TB3

D-M

A1*

D-M*

TB5

See Note 5

N/C

TB4

D-S

A2*

D-S*

MOV-3

See Note 5

A1*

29 41

16A2A1

A2*

RS-232

RS-232 to RS-485

converter with

surge suppression

Data 1 Data* 2 Ground 3

RS-485

N/C

Earth Ground

(See Note 4)

Host

RS-232 PORT 1

Network Port A

MOV-1

See Note 5

A1*

29 41

Network Port B

16A2A1

A2*

RS-232 PORT 2

N/C

4.2.2 Single-Ended Loop

The single-ended loop topology is the loop topology described above except that only one end of the loop is connected to the Host as shown in Figure 4.2. The single-ended loop is wired by cabling from the Host port to the ﬁrst ﬁeld unit port A1. Port A2 of this ﬁeld unit is then connected to port A1 of the next ﬁeld unit. This continues until the last ﬁeld unit is connected. (If a stub cable is run from port A2 of the last ﬁeld unit to a planned ﬁeld unit location, or the last ﬁeld unit is disconnected, the end of the cable must be terminated with a 120 ohm resistor to prevent unacceptable signal reﬂections.) The connection of the single-ended loop is identical to the redundant loop except that in the single-ended loop the connection from the last ﬁeld unit to port 2 of the Host is omitted.

The single-ended loop topology utilizes the ﬁeld unit repeater circuitry that maximizes the number of ﬁeld units and distance inherent with the loop topology. The single-ended loop is inherently less reliable than the redundant loop topology because the Host can only reach the ﬁeld units from one direction. It is, however, more reliable than the single-line multi-drop because a break or a short will only prevent communication with the ﬁeld units beyond the break or short.

Figure 4.2 – DDC-100 Single-Ended Loop Network

Legend

MOV

- Motor-Operated Valve

- Data A1

- Data A1*

Host

RS-232 PORT 1

N/C

Network Port A

- Data A2

41 29

- Data A2*

D-M

- Data A1 (UEC-3-DDC)

- Data A1*(UEC-3-DDC)

D-M* D-S

- Data A2 (UEC-3-DDC)

- Data A2* (UEC-3-DDC)

D-S*

- Shield

N/C

- No Connection

Data terminal is positive with respect to data* terminal

RS-232 to RS-485

converter with

surge suppression

RS-232

Data 1 Data* 2 Ground 3

RS-485

Earth Ground

(See Note 4)

N/C

TB4

D-S

A2*

D-S*

Notes:

1) Belden 3074F, 3105A, or 9841 shielded cable is recommended.

2) Correct polarity for ﬁeld unit and network controller connection is necessary for proper operation.

3) Connections shown are typical. The number of MOVs shown may not indicate true system size.

4) Earth ground: ground rod

5) Earth ground: ground rod or lug in

actuator if actuator is grounded.

MOV-250

TB5

See Note 5

MOV-249

See Note 5

TB3

D-M

A1*

D-M*

N/C

A1*

16A2A1

A2*

Diagnostic Note:

Polarity and level of the network’s data connection can be checked by measuring voltage between data and data* terminals. This voltage should be greater than +200 mVDC with network controller network ports disconnected.

Earth Ground Note:

If low impedance earth ground is not available at each actuator, contact engineering for alternative earth ground surge protection strategies.

MOV-248

N/C

TB4

TB3

TB5

See Note 5

D-M

A1*

D-M*

Notes:

1) Belden 3074F, 3105A, or 9841 shielded cable is recommended.

2) Correct polarity for ﬁeld unit and network controller connection is necessary for proper operation.

3) Connections shown are typical. The number of MOVs shown may not indicate true system size.

4) Earth ground: ground rod

5) Earth ground: ground rod or lug in

RS-232 to RS-485

converter with

surge suppression

RS-232

Data 1 Data* 2 Ground 3

RS-485

actuator if actuator is grounded.

N/C

Earth Ground

(See Note 4)

TB4

D-S

D-S*

MOV-1

See Note 5

A1*

29 41

MOV-250

TB5

See Note 5

MOV-3

MOV-2

16A2A1

A2*

N/C

TB3

D-M

A1*

D-M*

TB3

D-M

A1*

D-M*

TB5

See Note 5

MOV-249

See Note 5

A1*

16A2A1

N/C

A2*

N/C

TB4

D-S

A2*

D-S*

See Note 5

A1*

16A2A1

A2*

MOV-248

N/C

TB4

D-S

A2*

D-S*

TB5

See Note 5

N/C

TB3

D-M

A1*

D-M*

Diagnostic Note:

Earth Ground Note:

If low impedance earth ground is not available at each actuator, contact engineering for alternative earth ground surge protection strategies.

D-S

A2*

D-S*

30 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 31

4.2.3 Single-Line Multi-drop

The single-line multi-drop topology is shown in Figure 4.3. Single-line multi-drop is wired by cabling from the Host and connecting to the ﬁrst ﬁeld unit port A1. The cable to the next ﬁeld unit is attached to the same terminals on the ﬁrst ﬁeld unit and then run to port A1 on the second ﬁeld unit. This continues until the last ﬁeld unit is connected.

A single-line multi-drop topology can simplify installation (especially when pre-existing wiring is used), but it does not offer the extra reliability of a looped communication path. A line break prevents communication with ﬁeld units beyond the break, and a line short will cause a loss of communication with all ﬁeld units.

The maximum number of ﬁeld units that can be accommodated by the single-line multi-drop network is 28 units and the maximum distance between the Host and the last ﬁeld unit is 1800 feet (550 m) without the use of repeaters. Note that all Limitorque ﬁeld units can be wired to act as repeaters by using ports A1 and A2.

Flowserve recommends use of the single-ended loop topology in lieu of single-line, multi-drop for the MX-DDC.

NOTE: The single-line multi-drop topology requires the removal of termination resistors and bias voltage jumpers from all but the last ﬁeld unit. See the appropriate ﬁeld unit manual or contact Flowserve for assistance.

Figure 4.3 – DDC-100 Single-Line Multi-Drop Network

Host

RS-232 PORT 1

Network Port A

RS-232 to RS-485

converter with

RS-232

surge suppression

Data 1 Data* 2 Ground 3

RS-485

Earth Ground (See Note 4)

N/C

MOV-1

TB3

D-M D-M*

A1*

See Note 5

TB4

TB5

A1*

Legend

MOV

- Motor-Operated Valve

D-M

- Data A1 (UEC-3-DDC)

- Data A1*(UEC-3-DDC)

D-M* D-S

- Data A2 (UEC-3-DDC)

- Data A2* (UEC-3-DDC)

D-S*

- Shield

N/C

- No Connection

Data terminal is positive with respect to data* terminal

MOV-2

N/C

TB3

D-M D-M*

A1*

See Note 5

TB4

TB5

A1*

MOV-3

N/C

TB3

D-M D-M*

A1*

See Note 5

TB4

TB5

A1*

TB4

D-S

D-S*

Notes:

1) Belden 3074F, 3105A, or 9841 shielded cable is recommended.

2) Correct polarity for ﬁeld unit and network controller connection is necessary for proper operation.

3) Connections shown are typical. The number of MOVs shown may not indicate true system size.

4) Earth ground: ground rod

5) Earth ground: ground rod or lug in

actuator if actuator is grounded.

MOV-28

TB5

See Note 5

MOV-27

TB3

D-M

A1*

D-M*

A1*

N/C

D-M D-M*

A1*

See Note 5

TB4

N/C

TB5

Diagnostic Note:

Earth Ground Note:

If low impedance earth ground is not available at each actuator, contact engineering for alternative earth ground surge protection strategies.

TB4

MOV-26

TB5

See Note 5

TB3

D-M

A1*

D-M*

4.3 Network Polling

Network polling is a Host-generated systematic request for information from each ﬁeld unit on the serial communication network. This systematic process updates the Host Data Table (Poll Table) with each complete network scan. By utilizing this sequential update sequence, the Host can operate more efﬁciently because the Data Table always contains up-to-date information.

In systems in which there is no up-to-date Data Table, the Host must check the status of a ﬁeld unit every time it needs to actuate a valve. This check is required to determine if the actuator is capable of movement prior to the issuance of the command to move. The continuous poll process should be enabled at all times to allow peak network performance.

N/C

Safeguards are built into the Limitorque ﬁeld units that operate in the event of a disruption in the polling process. The ﬁeld unit network watchdog timer will start a ﬁeld unit reset process if the ﬁeld unit does not recognize that it has been polled in a speciﬁed time interval (default 60 seconds). This ﬁeld unit reset process is designed to clear any errors in the ﬁeld unit that may prevent successful communication to a Host device.

32 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 33

Causes of inability to communicate (fail to respond within the watchdog timer interval) can range from faulty network wiring, receipt of garbled or poorly constructed messages, multiple simultaneous Host queries, Host queries faster than ﬁeld unit responses, or Host shutdown. In a normally functioning actuator network, the ﬁeld unit reset process will not be activated.

The UEC-3-DDC factory default setting (changeable through ﬁeld unit Register 112) for the network watchdog timer is 60 seconds. If the ﬁeld unit is not polled within this time interval, the ﬁeld unit will reset its UART in an attempt to re-establish communication with the Host. This process of waiting for a poll and UART resets will occur a total of three times. After three cycles, the ﬁeld unit microprocessor CPU will be reset. The ﬁeld unit will then remain inactive and wait for network communication without further resetting. If a valid query is received, the network watchdog timer is restarted.

The MX-DDC does not perform a complete ﬁeld unit reset. After 60 seconds without communication, the MX-DDC Field Unit will set the appropriate bit and indicate a communication loss on Channel A1 (Channel A) or A2 (Channel B) or both.

Table 4.2 – Average Network Scan Time (seconds)

Number of

Field Units

10 .40 .94 .50 1.4 .61 1.9

20 .80 1.9 .98 2.8 1.3 3.8

40 1.6 3.9 2.0 5.6 2.5 7.6

50 2.3 5.0 2.9 7 3.8 9.6

100 4.6 11 6 15 6.5 20

200 9.2 24 10 32 13 43

250 11.5 32 12 42 16 56

Note 1: Network Protocol - Modbus RTU

Communication Settings - 9600 baud, parity - none, data bits = 8, stop bits = 1 Network Cable - Belden 3074F, 3105A, and 9841

Scan Time 1 Register

per Field Unit

MX-DDC UEC-3-DDC MX-DDC UEC-3-DDC MX-DDC UEC-3-DDC

Scan Time 5 Registers

per Field Unit

Scan Time 10 Registers

per Field Unit

NOTE: Each ﬁeld unit reset (UART or CPU) may take 10 to 15 seconds to perform, during which

Host communications, queries, and commands are not accepted.

Four other important points concerning network polling

1) The information that is requested from each ﬁeld unit can be the same for every ﬁeld unit, or each ﬁeld unit may be requested to return a unique set of information.

2) When sending commands to the ﬁeld units, the Host should always wait until a command is acknowledged before sending another command. This will prevent communication collisions on the network.

3) The network can have only one Master device at a time. Simultaneous Masters are not permitted.

4) Host time-out should be greater than 200 ms.

The network scan time for a Modbus Network depends on the number of registers requested from each device and the number of devices attached to the network. Tables 4.1 and 4.2 provide guidelines for calculating average ﬁeld unit poll times and average network scan times. The Modbus function code 03 was used to obtain this information.

Tables 4.1 and 4.2 do not include Host delay between each poll. Host delays between each poll are variable for each Host. The Host turn-time from receipt of poll to issuance of next poll should be greater than 20 ms and less than 50 ms.

Table 4.1 – Average Field Unit Response Time

Number of MX-DDC Query Send/ UEC-3-DDC Query Send/

Registers Receive Time (ms) Receive Time (ms)

1 40 71

5 50 109

10 62 162

Note 1: Network Protocol - Modbus RTU

Communication Settings - 9600 baud, parity - none, data bits = 8, stop bits = 1 Network Cable - Belden 3074F, 3105A, and 9841

Example

An MX-DDC Network with 20 ﬁeld units with 5 registers per ﬁeld unit being polled will have an average total network scan time of .98 seconds. Host message turn-time per

ﬁeld unit must be added to this number. (Typical open/close or close/open operating times for motor-operated valves is 30 to 90 seconds.)

4.3.1 Network Communication Errors

In understanding how network communication errors should be handled, a brief discussion deﬁning the difference between ﬁeld unit communication fault status and Host communication fault status should be helpful. In a typical Limitorque DDC-100 Network, there are two levels of Channel A and Channel B fault.

The ﬁrst level is the ﬁeld unit level. In each DDC-100 Field Unit, there are Channel A/B Fault bits located in Register 9, bits 10 and 11 respectively. These bits are set by the ﬁeld unit as a result of successful communication with the Host over the network.

For UEC-3-DDC and I/O module-based ﬁeld units, the Channel A bit monitors the standard communication Channel A (ports A1 and A2) for redundant loop communications. The Channel B bit monitors the optional Channel B (ports B1 and B2). Channel B is a second port that is used for dual redundant loop communications.

In a redundant loop network with no faults, the UEC-3-DDC Field Unit will report Channel A with

no fault (Reg. 9, bit 10 – contents = 0), but Channel B will indicate a fault condition (Reg. 9, bit 11 – contents = 1). The Channel A fault bit is 0 because the eld unit Channel A is active with no faults,

while Channel B is 1 because the optional granddaughter board for Channel B is not installed or in use.

For MX-DDC-based ﬁeld units, the Channel A bit monitors the communication Channel A1 (terminal points 15 and 16) and the Channel B bit monitors communication Channel A2 (terminal points 29 and 41) for redundant loop communications (the MX-DDC does not support dual redundant loop communications).

In a redundant loop network with no faults, the MX-DDC Field Unit will report Channel A with no

fault (Reg. 9, bit 10 – contents = 0) and Channel B with no fault (Reg. 9, bit 11 – contents = 0).

This level of communication-error reporting is used for local ﬁeld unit communication diagnostics. Should a Host not be able to communicate with a ﬁeld unit, the Host will not be able to retrieve this or any other status information to indicate error conditions.

34 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 35

The second level of monitoring Channel A/B fault occurs at the Host and provides communication information for utilization by the Host. When a Host is conﬁgured with two network serial ports, one port is designated as Channel A (Port 1) and the other port is designated as Channel B (Port 2).

During the course of polling, the Host will retrieve the ﬁeld unit status register that contains the ﬁeld unit-deﬁned status of Channel A/B fault described above. The Host may overwrite the retrieved ﬁeld unit Channel A/B faults (ﬁeld unit Register 9 bits 10 and 11) in the Host’s memory to indicate communication status between the Host serial ports (A and B) and each ﬁeld unit.

Channel A and Channel B fault bits may equal a 1 or 0 depending on the Host’s requirement of a 1 or 0 to indicate successful communication. This provides an accurate indication of the communication status from both Host Serial ports to each ﬁeld unit. Typically, this type of communication-fault recording is consistent with Hosts containing “C”-based programs.

An equally effective method for recording the communication status between the Host’s two network serial communication ports and networked ﬁeld units is to create a separate memory location in the Host for recording Channel A/B fault status. This memory location may be conﬁgured so a register, say Register X, bits 0 and 1 are ﬁeld unit 1 Channel A/B fault status, bits 2 and 3 are ﬁeld unit 2 Channel A/B fault status and so on.

Another permutation of this method is to conﬁgure the Host memory so Register X contains the Channel A fault status for the ﬁrst 16 ﬁeld units and Register X+1 contains the Channel B fault statuses for the ﬁrst 16 ﬁeld units and so on.

It should be remembered that a Host with only one serial communications port will not have the ability to handle redundant loop network communications. Therefore, communication status will be limited to only one channel.

NOTE: In the Direct-to-Host architecture, Channel A and B faults need to be set by the Host. Setting these faults will allow the system integrator to establish ﬁeld unit time-out, retry, and ﬁeld unit communication status.

with the ﬁeld unit are not successful from the second port, the corresponding Channel Fault bit will be set to 1, and the Host will resume polling on the original port. Once the Host has completed polling all conﬁgured ﬁeld units on the ﬁrst port, the polling routine will switch to the other port and repeat the above process.

Example

There are ﬁve ﬁeld units on a network (redundant loop topology) and ﬁeld unit number 3 has been turned off. The Host is currently polling ﬁeld units through Host port 1 (Channel A). Field unit numbers 1 and 2 respond to the Host port 1 poll. Field unit number 3 does not respond to the port 1 poll causing the Host to set ﬁeld unit 3 Channel A Fault bit to 1. The Host now changes to port 2 (Channel B) and polls ﬁeld unit number 3. Field unit number 3 does not respond to the port 2 poll, causing the Host to set the ﬁeld unit 3 Channel B Fault bit to 1. Next, the Host changes back to port 1 and attempts to poll ﬁeld unit number 4. This communication attempt is successful and the Host now polls ﬁeld unit number 5 through Host port 1. Field unit number 5 responds, completing the port 1 poll.

Next, the Host repeats the process through Host port 2 (Channel B). Field units 1 and 2 respond, ﬁeld unit 3 does not respond, and the Host sets the ﬁeld unit 3 Channel B Fault bit to 1. The Host changes to port 1 (Channel A) and attempts to communicate with ﬁeld unit 3. Field unit 3 does not respond. The Host sets the ﬁeld unit 3 Channel A Fault bit to 1, switches back to port 2, and resumes polling the remainder of the conﬁgured ﬁeld units. Once ﬁeld units 4 and 5 have been successfully polled via port 2, the Host then switches to port 1 and repeats the polling process. The intermediate alternating port process described above continues until ﬁeld unit 3 is powered on and the communication fault clears. (See Example 2 in this section.)

Commands for ﬁeld unit control should interrupt the polling process and be issued through the current poll port. Once the ﬁeld unit has acknowledged the command, the Host resumes the polling process. In the event of a communication fault between the current poll port and a commanded ﬁeld unit, the Host should issue the command through the other communication port.

4.3.2 Network Communication Examples

The following write-ups and examples indicate proven polling techniques. The programmer who adheres to these various examples will ﬁnd their projects easier to implement.

ALL EXAMPLES SHOWN DEPICT A NETWORK IN WHICH THE HOST IS OVERWRITING THE RETRIEVED FIELD UNIT CHANNEL A/B FAULT BIT (FIELD UNIT REGISTER 9, BITS 10 AND 11). The programmer has the choice of overwriting these communication fault bits or creating a separate communication fault table in the Host’s memory as detailed in Section 4.3.1, Network Communication Errors.

In Redundant Loop Mode, the Host provides communication redundancy to each conﬁgured ﬁeld unit on the network. The Host monitors the status of the communication path between port 1 and each conﬁgured ﬁeld unit and between port 2 and each conﬁgured ﬁeld unit. Host port 1 communication status between port 1 and the addressed ﬁeld unit is recorded in the ﬁeld unit Channel A Fault bit. Host port 2 communication status between port 2 and the addressed ﬁeld unit is recorded in the ﬁeld unit Channel B Fault bit. Both Channel A and Channel B Fault bits are located in the ﬁeld unit Status Register 9, bits 10 and 11 in the Host memory table.

On a fault-free network where all conﬁgured ﬁeld units are communicating, the Host will ﬁrst poll all ﬁeld units via port 1, then poll all ﬁeld units via port 2, back to port 1, and so on. As each ﬁeld unit is successfully polled, the respective Channel Fault bit is set to 0 in the Host’s ﬁeld unit Status Register. Remember the Host port 1 equals Channel A and the Host port 2 equals Channel B. (See Example 1 in this section.)

If a ﬁeld unit cannot be reached on a poll, the Host will set the corresponding Channel Fault bit to 1, switch to the other port and attempt to communicate with the same ﬁeld unit. If communications

Redundant Loop Network Truth Table Summarizing the results of Examples 1 through 4: Recorded in Host ﬁeld unit Status Register Bits 10 and 11

Field

unit #

1 0 0 0 0 0 1 0 1

2 0 0 0 0 0 1 0 1

3 0 0 1 1 0 1 0 1

4 0 0 0 0 1 0 0 1

5 0 0 0 0 1 0 0 1

Example 1 Example 2 Example 3 Example 4

Ch. A Ch. B Ch. A Ch. B Ch. A Ch. B Ch. A Ch. B

Example 1: No faults

The Host is successfully communicating with each ﬁeld unit and sets the bits for Channel A and B Fault to 0. A value of 0 in Channel A and B Fault indicates successful communication.

Example 2: A ﬁeld unit is off-line

The Host is successfully communicating with ﬁeld units 1, 2, 4, and 5 via both ports. Field unit number 3 is without power that causes the ﬁeld unit 3 network board bypass relays to de-energize. This de-energization of the bypass relays shorts the signal through the network board and isolates ﬁeld unit 3 from the DDC-100 Network.

Example 3: A break or short in the redundant loop

The Host is successfully communicating with ﬁeld units 1, 2, and 3 via port 1, and ﬁeld units 4 and 5 via port 2. When a ﬁeld unit doesn’t communicate within a predetermined time-out period, the Host sets the corresponding Channel Fault bit to a value of 1. This example indicates a wiring problem between ﬁeld units 3 and 4. This problem is typically a cable breakage, short, or improperly terminated wire.

36 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 37

Example 4: Loss of 1 of 2 Host Ports

The Host is attempting to communicate with the ﬁeld units via both ports but is unable to reach any ﬁeld units via port 2. This typically indicates a broken cable connection at port 2 or at the ﬁrst ﬁeld unit from port 2, broken or shorted cable between the Host and the ﬁrst ﬁeld unit from port 2, improperly terminated wires, or loss of power to the RS-232/485 converter if attached to the Host port 2.

Non-Looped Network Truth Table via Port 1 (Channel A) Polling Only Summarizing the results of Examples 5 through 7: Recorded in Host ﬁeld unit Status Register bit 10. Bit 11 Channel B is always 0 as set by the Host

Field unit #

1 0 0 0 0 0 0

2 0 0 1 0 0 0

3 0 0 0 0 1 0

4 0 0 0 0 1 0

5 0 0 0 0 1 0

Example 5: No faults

The Host is successfully communicating with each ﬁeld unit and sets the bit equating to Channel A Fault to 0. A value of 0 in the Channel A Fault bit indicates successful communication.

Example 5 Example 6 Example 7

Ch. A Ch. B Ch. A Ch. B Ch. A Ch. B

integrator can use to write a unique user-interface for polling and commanding the valve actuator network. All Modbus commands for polling or commanding are implemented in a user-developed software driver.

The advantage of this method of control is that any system integrator familiar with process control, Visual Basic, or C++ can write a unique application. This approach provides the user with ﬂexibility to use the software at many sites without repeatedly purchasing site licenses for Modbus driver software or application packages.

4.4.3 Personal Computer with a Graphical User-Interface

A Graphical User-Interface (GUI) software package can be used to communicate directly with the DDC-100 Network without communicating through a dedicated data concentrator. This control of the network requires a Modbus Driver for the GUI that is compatible with the Modbus function codes supported by a DDC-100 Field Unit. The network communication will follow the polling and command rules established by the individual application.

Most GUI Modbus drivers do not toggle the PC RS-232 serial port RTS/DTR line. The Limitorque Self-Steered RS-232/485 converter will enable communication between the PC and the DDC-100 Network.

Examples of GUIs include, but are not limited to, Wonderware InTouch, PCSoft Wizcon, Intellution FixDMACS, and Genesis Iconics.

Example 6: A ﬁeld unit is off-line

The Host is successfully communicating with ﬁeld units 1, 3, 4, and 5. Field unit 2 does not respond, causing the Host to set ﬁeld unit 2 Channel A Fault to 1. In this example, ﬁeld unit 2 is without power, causing the ﬁeld unit 2 network board bypass relays to de-energize. This de-energization of the bypass relays shorts the signal through the network board and isolates the ﬁeld unit from the DDC-100 Network.

Example 7: A break or short in the network

The Host is successfully communicating with ﬁeld units 1 and 2 but is not able to communicate with ﬁeld units 3, 4, and 5, causing the Host to set ﬁeld unit 3, 4, and 5 Channel A Fault to 1. This typically indicates a broken or shorted cable between ﬁeld unit 2 and 3, a broken cable connection at ﬁeld units 2 or 3, improperly terminated wires at ﬁeld unit 2 or 3, or loss of power to ﬁeld units 3, 4, and 5.

4.4 Network Control

4.4.1 Ladder Logic Routines

The PLC running a ladder logic program is capable of being an integral part of any valve actuator network. All commands for network polling and valve positioning may be generated by the PLC and sent through a Modbus Master communications port to the valve actuator network. This port is typically located on a PLC component or installed on a PLC-compatible third party Modbus interface module. These modules may contain either one or multiple Modbus ports.

NOTE: This category of off-the-shelf, PC-based software also includes numerous Supervisory Control and Data Acquisition (SCADA), Human Machine Interface (HMI), and Hybrid real-time system conﬁguration and development software packages.

Examples of this type of interface include, but are not limited to A-B PLC-5, A-B SLC-500, Square D PLC, Modicon 984, Modicon Quantum, Compact or Micro PLC, Siemens S5 115U, or Simatic TI-545/555.

4.4.2 Software Control Modules (C++ or Visual Basic Program)

The use of Visual Basic or C++ allows the user to totally customize the individual application to meet application speciﬁc requirements. The user can create a functional speciﬁcation that a system

38 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 39

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Interfacing

Hardware for the DDC-100 Network

The Flowserve Limitorque DDC-100 Network uses the RS-485 electrical standard for the network communications medium. Because RS-232 ports are standard on most popular Host devices, Limitorque offers two RS-232 to RS-485 converters. These converters contain circuits that electrically isolate the Host, improve noise immunity, and protect it from high-level voltage surges that may be induced into the network.

RS-485 is used for the network electrical standard because it is capable of communicating data at high rates over relatively long distances, and may be used in redundant loop or multi-drop network topologies.

5.1 RS-232 to RS-485 Converters

Limitorque has sourced two models of the RS-232 to RS-485 converters. The primary distinction between these models is self or auto-steering vs. steered as detailed in this section. The models can be distinguished by the part numbers on the case of the converter. The speciﬁcations for both models are given in Table 5.1. The dimensions of the converter enclosures are given in Figure 5.1 and the cable to connect the converter to a 25-pin serial port is shown in Figure 5.2.

40 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 41

25-Socket Female

Table 5.1 – RS-232/RS-485 Converter Speciﬁcations

Parameter Speciﬁcation

Baud Rate 600 baud to 62.5 kb

Protocols Modbus, BITBUS

Connectors RS-232 - DB9 Male

RS-485 - Detachable ﬁve-contact (Steered Converter P/N 61-825-0966-4)

RS-485 - Detachable three-contact (Self-Steered Converter P/N 61-825-1032-4)

Indicators PWR1, PWR2, TxD, RxD, RTS/DTR (Steered Converter P/N 61-825-0966-4)

RS-232 - Power, TxD, RxD

RS-485 - Power, TxD, RxD

(Self-Steered Converter P/N 61-825-1032-4)

Surge Protection In accordance with IEC-801.5 to 1.5 kV

Power 110 - 220 VAC 50/60 Hz, single-phase

10 W, Switch Selectable

Fuse 250 VAC, .25 A

Operating Temperature Range 0 to 70°C (32 to 158°F)

Operating Humidity 95% Relative (Non-condensing)

The ordering information for the two converter types is given in Tables 5.2 and 5.3.

Table 5.2 – Steered Converter Assembly (P/N 22300-7591)

Description Part Number Quantity

Complete converter w/AC power cord 61-825-0966-4 2

Cable, RS-232, DB25M to DB9F, 6 feet long ESC-AT-PS/2Cable 2

Three-unit bracket for 19" rack mounting ES5-K1PT-H03B 1

Blank insert panel for three-unit rack ES5-19216-001B 1

Note 1: Individual assembly components may be purchased from Flowserve.

Table 5.3 – Self-Steering Converter Assembly (P/N 22300-7601)

Description Part Number Quantity

Complete converter w/AC power cord 61-825-1032-4 2

Cable, RS-232, DB25M to DB9F, 6 feet long ESC-AT-PS/2Cable 2

Three-unit bracket for 19" rack mounting ES5-K1PT-H03B 1

Blank insert panel for three-unit rack ES5-19216-001B 1

Note 1: Individual assembly components may be purchased from Flowserve.

Figure 5.1 – RS-232/RS-485 Converter Dimensions and Rack Mount Kit

End View

Front View

1.12

Rack Mounting Kits End View

1.72

V F

18.95 (For standard 19" rack)

Figure 5.2 – RS-232/RS-485 Cable Diagram

Connector to A/B Serial Expander Comm 2&3

Transmit Ou t Receive In Signal GND RTS Out (Used for steering)

Shell Shield

2 3 7 4

25-Pin Male

2 3 4 5 6 7

8 20 22

Limitorque P/N ESC-BC 00801

For use with RS-232/RS-485 Converter

P/N 61-825-0900-3 only .

Limitorque P/N ESC-AT-PS/2Cable

for use with RS-232/RS-485 Converters

P/N 61-825-0966-4 and P/N 61-825-1032-4

inches mm

A 5.6 141.5

B 1.5 38.6

C 6.0 152.4

D 0.2 5.3

F 5.2 130.9

V 5.0 128

Connector to RS-232/485 Converter

Transmit In Receive Ou t

Signal GND

RTS In

9-Pin Female

3 2 7 8 6 5 1 4 9

Shell Shield

Converter assemblies 22300-759 and 22300-760 include two DB25M to DB9F modem cables. These cables are appropriate for most Host connections. To determine if these cables are compatible with your Host RS-232 communication port(s), contact your System Integrator.

The System Integrator will review wiring requirements for the Host RS-232 port(s) with the converter-assembly cables. Should the cables not be compatible with the Host RS-232 port, the cables may be altered, a modifying connector installed, or new cables may be purchased at a local cable supplier.

Individual converter part numbers 61-825-0966-4 and 61-825-1032-4 do not include a serial cable for connection to a Host. It is the responsibility of the System Integrator to obtain the correct serial cable based on the Host RS-232 port connector and Limitorque converter RS-232 port connector.

5.1.1 RS-232/RS-485 Control Line Steered Converter (P/N 61-825-0966-4)

This is the standard converter offered by Flowserve for use with Limitorque networks. This converter provides isolation, surge protection, data rate, and distance capability that is equivalent to the self-steered converter. This converter uses either Host RS-232 port RTS (Request To Send) or DTR (Data Terminal Ready) (DIP switch selectable) signals to steer the RS-485 data direction. This converter also provides a directional steering output for Limitorque’s A/B Switch (P/N EEC-

90001840).

In the converter, the RS-232 data is converted to TTL signals. The signals drive indicating LEDs and inputs of optical couplers that drive the RS-485 converter circuit. The optical couplers isolate the Host hardware from the RS-485 Network. The RS-485 circuit is bi-directional and must be steered

42 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 43

to place it in the transmit or receive mode. This converter requires that the Host serial port driver software must toggle RTS or DTR in order to steer the converter.

There are ﬁve LED indicators, one DIP switch, two connectors, and a selector switch to select between 110 and 220 VAC power. The placement of the indicators, switches, and connectors is shown in the photographs of the front and back panels of the converter enclosure in Figure 5.3. All jumpers are located inside the enclosure. The LEDs are labeled with their functions, and the DIP switch, connectors, and jumpers are detailed below:

Figure 5.3 – Front and Back Panels of Steered Converter

Table 5.4 – RS-232/RS-485 Converter (P/N 61-825-0966-4) DIP Switch Functions

Switch Function

Down RTS Steering (Default)

4 Up (Default)

5 Up (Default)

6 Up (Default)

7 Up (Default)

8 Up (Default)

Up RTS Steering OFF

Down DTR Steering

Up DTR Steering OFF (Default)

Down Normal Steering, Transmit when RTS or DTR high (Default)

Up Inverted Steering, Transmit when RTS or DTR low

Table 5.6 – RS-232/RS-485 Converter (P/N 61-825-0966-4) RS-485 Connector

RS-485

Connector

Pin Number

Note 1: Indicates negative side of signal.

Note 2: Must be connected to earth ground to ensure surge protection.

WARNING: Disconnect the converter from the power source and from the Host and

Function

1 Data

2 Data*

3 Earth ground

4 RS-485 RTS steering

5 RS-485 RTS*

ground

steering

network before removing the cover. Potentially lethal voltages are present inside the enclosure when it is connected to the power source.

Table 5.7 – RS-232/RS-485 Converter (P/N 61-825-0966-4) Jumpers

Jumper

JP1 and JP2

JP3 and JP4

JP5

Note 1: The jumpers JP1 through JP5 are located inside the converter. The enclosure must be opened for access. The positions for the jumpers are shown in the silkscreen on the PC board.

Function

Bias and line termination for RS-485 data lines

Position 1:2 (ON) adds bias and termination

Position 2:3 (OFF) removes bias and termination

Both jumpers must be set to the same position

Bias and line termination for RS-485 steering lines

Position 1:2 (ON) adds bias and termination

Position 2:3 (OFF) removes bias and termination

Both jumpers must be set to the same position

Reverses RS-232 TxD and RxD lines

DCE 1:3, 2:4

DTE 3:5, 4:6 (Default)

5.1.2 RS-232/RS-485 Converter with RS-485 Self-Steering (P/N 61-825-1032-4)

This converter provides the same network capabilities as the steered converter, but this converter

Table 5.5 – RS-232/RS-485 Converter (P/N 61-825-0966-4) RS-232

does not require the RTS or DTR signals from the Host RS-232 port.

Connector

RS-232

Connector

Pin Number

Note 1: The pin numbers of these signals can be reversed with jumpers inside the converter box (see Table 5.7).

44 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 45

Function

1 Carrier Detect

2 Transmit Data (TxD)

3 Receive Data (RxD)

4 DTR

5 Signal Ground

6 DSR

7 RTS (in)

There is a patented self-steering circuit in this converter that senses the direction of data, processes the data, and retransmits it via the appropriate output port. The data is processed using a noise elimination circuit ensuring that only valid data is retransmitted. Received data is sent to the selfsteering circuit for proper port direction control and signal processing. The data bits are checked, recentered, and reclocked before being directed to the proper output port.

Six LED indicators, two connectors, and a selector switch to select between 110 and 220 VAC power are located on the enclosure. The placement of the indicators, connectors, and the switch is shown in the photographs of the front and back panels in Figure 5.4. All jumpers are located inside the enclosure. The LED indicators are labeled with their functions, and the connectors and jumpers are detailed below:

Figure 5.4 – Front and Back Panels of Self-Steering Converter

Table 5.8 – RS-232/RS-485 Converter (P/N 61-825-1032-4) RS-232 Connector

RS-232

Connector

Pin Number

2 Transmit data (TxD)1

3 Receive data (RxD)1

5 Signal ground

Note 1: The pin numbers of these signals can be reversed with jumpers inside the converter box (see Table 5.10).

Function

Table 5.9 – RS-232/RS-485 Converter (P/N 61-825-1032-4) RS-485 Connector

RS-485

Connector

Pin Number

1 Data

2 Data*1

3 Earth ground2

Note 1: Indicates negative side of signal.

Note 2: Must be connected to earth ground to assure surge protection.

WARNING: Disconnect the converter from the power source and from the Host and

Function

network before removing the cover. Potentially lethal voltages are present inside the enclosure when it is connected to the power source.

Table 5.10 – RS-232/RS-485 Converter (P/N 61-825-1032-4) Jumpers

Jumper Function

Bias and termination for RS-485 data lines

JP1 and JP2

JP3

JP4

JP5

JP6

JP7

JP8

Note 1: The jumpers JP1 through JP8 are located inside the converter. The enclosure must be opened for access. The positions for the jumpers are shown in the silk screen on the PC board.

Note 2: High-Level Data Line Control

Position 1:2 Adds bias and termination

Position 2:3 Disables bias and termination

Both jumpers must be in the same position

BAUD Rate Select

Position 0 Not Used

Position 1 62.5K

Position 2 38.4K

Position 3 19.2K

Position 4 9600

Position 5 4800

Position 6 2400

Position 7 1200

Position 8 600

Position 9 N/A

Position 10 N/A

Protocol Select

Position 1:2 BITBUS

Position 2:3 Modbus

Reverses RS-232 TxD and RxD lines

DCE 1:2, 3:4

DTE 1:3, 2:4

XTAL Select.

Position 1:2 62.5 Baud

Position 2:3 Standard Baud

Asynchronous or HDLC

Position 1:2 HDLC

Position 2:3 Asynchronous

Filter Ground

Position 1:2 Common Ground

Position 2:3 Isolated Ground

46 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 47

5.2 RS-485 Connection Direct to the DDC-100 Field Unit

The RS-232/RS-485 converters that are sourced by Flowserve were speciﬁcally designed to comply with the EIA RS-232 and the EIA RS-485 data transmission standards and to protect the DDC-100 Network and the Host device. The successful operation of a large number of installed systems has demonstrated the robustness and reliability of these converters. Flowserve strongly recommends the use of these converters for all DDC-100 applications in which the Host has RS-232 ports available. The use of these converters in most cases will simplify the installation and commissioning of the DDC-100 Network.

If the user wishes to attach a Host device to the DDC-100 Network through other RS-232/RS-485 converters or directly from Host RS-485 ports, the following guidelines must be followed:

1) The Host ports that attach to the DDC-100 Network must adhere to the EIA RS-485 Standard.

The DDC-100 Network only uses the DATA, DATA*, and earth ground terminals. The following additional details are provided for interfacing guidance to the Limitorque DDC-100 Network:

a) The network signal is based on +5 Volts and typical line voltage levels are

0 to 4.5 Volts.

b) Network biasing for the MX-DDC RS-485 data lines:

• terminals 15 and 16 (A1) 570 mV

• terminals 29 and 41 (A2) 280 mV

Network biasing for the UEC-3-DDC RS-485 data lines:

• D-M and D-M* (A1) 208 mV

• D-S and DS* (A2) 208 mV

Bias voltage is measured without the network attached to the ﬁeld unit RS-485 communications ports.

c) DATA is the most positive voltage and DATA* is the least positive voltage level.

d) When using RS-485 direct (without Limitorque RS-232/RS-485 converter), the user is

responsible for ensuring proper surge protection between the network and the Host device.

e) Each Host port must be resistively terminated with 120 ohms to prevent line

reﬂections.

Programming

Programming the Host to control a DDC-100 Network of Flowserve Limitorque Field Units will require information about the design of the network. Flowserve recommends gathering this information before starting the program. After the program has been completed, the network should be fully tested before commissioning. The following recommendations are provided as the result of a number of successful installations:

1) Obtain a wiring diagram of the digital inputs and digital outputs to the controlled devices before programming the controller.

2) Develop a tag table for the installation. This table should include the tag name, network address, desired status indication, and command format (bit or register write).

3) If possible, test the program prior to site installation. This will provide a program veriﬁcation time for debugging.

4) Attach a protocol analyzer to the DDC-100 Network and monitor the timing, message structure, and message issuance to verify the Host code. This will assist in the diagnosis of proper command issuing and sequencing of the Host control algorithm.

Recommendations

f) The DDC-100 Field Units are certiﬁed in accordance with IEC 801-5 (EEC-EMC directive

89/336/EEC) to 1.5 kV communication lines.

2) After the Host has ﬁnished a transmission that requires a ﬁeld unit response, the Host transceiver must be turned before the ﬁeld unit begins transmitting data back to the Host. The ﬁeld unit can respond in 10 ms.

3) Earth ground should not be routed through sensitive electronic equipment. Connect the network cable shield directly to an effective local, low-impedance earth ground (less than 5 ohms).

48 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 49

6.1 Monitoring Field Unit Status

Network control involves two basic functions—monitoring ﬁeld unit status and issuing control commands. The following checklist is provided for monitoring the status of the ﬁeld units:

1) Determine the Host time-out period. Verify that the time-out period is of sufﬁcient duration to allow a ﬁeld unit response under the worst-case conditions (greater than 200 ms).

2) Limit the number of retries to a maximum of three. This will enable the Host to continue with the polling process without undue delays.

3) Do not allow more than one Master control of the network at any time. A Host with two serial ports should only have one actively in control at any time.

4) The actuator ﬁeld unit digital input 0 is factory defaulted for local ESD (Emergency Shutdown). For the MX-DDC or UEC-3-DDC, placing 24 VDC or 120 VAC (MX-DDC only) on this input will cause the ﬁeld unit to send the actuator to the default local ESD position of close. To use this digital input as a generic input, the local ESD setting must be set to Ignore.

5) Field unit register 10, bit 10 will only report network ESD when the ﬁeld unit network ESD parameter is set to any value but Ignore.

in increased network trafﬁc that increases network scan times. Also, repeating acknowledged commands can cause erratic ﬁeld unit operation (e.g., stop).

6) Field unit register 9, bit 5 (Valve Jammed) will only be active when the actuator is moving the valve and the torque switch is tripped.

7) In MOV (Motor-Operated Valve) mode, Field unit registers 9, 10, 11 bits are a value of 0 when false. A value of 1 indicates true.

8) In MOV mode, ﬁeld unit register 12 low-byte bits are a value of 0 when false. A value of 1 indicates true.

9) In MOV mode, ﬁeld unit register 12 bit 11 is default inverted, by default, to a value of 1 on false and 0 on true. The remaining bits in the high-byte are set, by default, to a value of 0 on false and 1 on true.

6.2 Issuing Control Commands

The following checklist is provided for issuing control commands:

1) The normal polling process should be interrupted to issue any control commands to a ﬁeld unit on the network. This interruption should take place after the Host receives the response from a previously issued query. Once the ﬁeld unit control command has been issued and the acknowledge returned, the normal polling process should resume.

2) Prior to issuing commands to an actuator-mounted ﬁeld unit:

• Verify successful communication. This is accomplished via the normal

polling process.

• Verify actuator is in Remote mode.

• Verify the actuator is capable of movement.

a) Combined Fault bit is not a value of 1.

b) Actuator is not at desired position. (Do not send open command

if actuator is in open position.)

c) Verify that the desired direction of travel does not have a torque

switch fault.

7) The ﬁeld unit will automatically stop (disengage contactor) when the actuator reaches the full open or close position. There is no requirement for issuing a Stop command when the actuator reaches the open or close limit switch.

8) A Stop command can be used to stop the actuator in mid-travel. When the actuator has stopped in mid-travel (between the open and close limit switches), the ﬁeld unit register 9 bit 02 (Stopped) will be true (1).

9) There is no requirement to ﬁrst issue a Stop command when changing directions from open to close or close to open. When the ﬁeld unit receives the command to change directions, the ﬁeld unit will ﬁrst disengage the contactor (stop the actuator), then engage the other contactor.

10) A network Stop command will stop the actuator if the selector switch is in Remote or Local mode. The actuator local Stop pushbutton will stop the actuator if the selector switch is in Remote or Local mode.

Table 6.1 – Sample Tag Table for Direct-to-Host applications

Tag Name Description

80-HS-4141A Open actuator 1 Command to open the valve 40001 256 (Dec)

80-HS-4141B Close actuator 1 Command to close the valve 40001 768 (Dec)

80-POS-4141 Position feedback 1 Valve position in % of Open 40008 n/a

80-STAT-4141 Status register 1 16 bits of status 40009 n/a

80-HS-4142A Open actuator 2 Command to open the valve 40001 256 (Dec)

80-HS-4142B Close actuator 2 Command to close the valve 40001 768 (Dec)

80-POS-4142 Position feedback 2 Valve position in % of Open 40008 n/a

80-STAT-4142 Status register 2 16 bits of status 40009 n/a

80-GO-5253A Initiate “move-to” 3 Initiate “move-to” 40001 6656 (Dec)

80-GO-5253B “move-to” value 3 % of Open value 40002 0-100 (Dec)

80-POS-5253 Position feedback 3 Valve position in % of Open 40008 n/a

80-STAT-5253 Status register 3 16 bits of status 40009 n/a

Modbus

Slave

Address

Comments

Modbus

Command

Data

3) Prior to issuing commands to an I/O Module-style ﬁeld unit:

• Verify successful communication. This is accomplished via the normal polling process.

• When using 2 relays to control a single device, always disengage the ﬁrst relay before engaging the second relay.

4) Commands can be issued with either the Modbus function code 05 or 06. Either command is capable of opening or closing the actuator or engaging or disengaging ﬁeld unit physical relays 1 - 6. If the actuator is conﬁgured for intermediate position control, Modbus function code 06 must be used to move the actuator to the desired position.

5) An actuator conﬁgured for intermediate position control (“move-to”) should be issued position commands between 2 and 98% of open. Issue open or close commands for 0 and 100% of open.

6) Commands issued to the ﬁeld unit should never be repeated if the command acknowledgment is received from the ﬁeld unit. Commands should be reissued only when the ﬁeld unit does not acknowledge receipt of the command. Repeated commands sent to the ﬁeld unit will result

50 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 51

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Typical DDC-100

Network Installation Assignments

Various project suppliers play important roles in the design, purchase, installation, and commissioning of a plant control system. A typical assignment of roles for the installation of a DDC-100 Network with its valve controllers is presented in this section. This material is presented for guidance only and is not necessarily representative of a particular installation.

Project supplier responsibilities

S.I. (System Integrator) Responsible for developing code to operate the plant per the speciﬁcation. This includes the interface between the DDC-100 Network and the Host. The System Integrator may be a third-party programmer or a site engineer responsible for computer programming.

Engineer (Project Engineer) Responsible for developing the site layout, speciﬁcations, and requirements for the project.

Contractor Responsible for site project development. The contractor is the site coordinator responsible for completing the upgrade or new facility installation per the speciﬁcation. This may be a third-party (independent) contractor or a site maintenance group.

Flowserve Limitorque Valve actuator manufacturer. Supplier of the valve actuators per the speciﬁcation.

OEM (Valve Original Equipment Manufacturer) Valve manufacturer responsible for providing valves per speciﬁcation to contractor or job site. The valve OEM may also provide the Limitorque actuators as a part of its scope of supply.

Fourth-Party Hardware/Software Supplier of hardware and/or software packages needed to complete system integrator’s scope of supply. Equipment typically includes: PLC racks, components, personal computers, Graphical User Interfaces, etc.

52 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 53

System Integrator Tasks

Deliverable From To Comments

Speciﬁcation Engineer S.I Detail functionality of system

Schedule Contractor S.I. Production Schedule

Manuals for DDC-100 Operation:

• LMAIM4019 Direct-to-Host Programming

Guide

• LMAIM1329 Accutronix Installation and

Operation for MX-DDC Field Unit

• LMAIM4029 DDC-100 UEC Field Unit

Manuals Limitorque S.I.

Hardware for system development

Fourth-Party

Hardware/Software

Actuator Contractor S.I.

Site Preparation Contractor S.I.

Operational System S.I. Contractor

Documentation S.I. Contractor

Contractor S.I.

Component supplier S.I.

(Modbus) Installation and Operation Manual

• LMAIM4030 DDC-100 UEC Field Unit Installation and Commissioning Manual

• LMAIM4022 DDC-100 UEC Field Unit

Wiring and Startup Guidelines

• Modicon Modbus Protocol Reference Guide

PI-MODBUS-300 Rev. G (available from Modicon)

Hardware may include: DDC-100 Field Units, RS-232/485 converters

Modbus interface modules, Modbus drivers, non-Limitorque converters, or surge suppression

Availability of DDC-100 Field Unit for testing developed application software

Complete actuator or ﬁeld unit installation. Provide actual (as installed) site loop diagram to System Integrator

Software only (code) or Hardware and Software (hardware and code)

System Operation and Maintenance Manuals, Operational characteristics of system, Network Addresses to equipment tag names

Engineer Tasks

Deliverable From To Comments

Speciﬁcation End-user Engineer Site and system requirements

Schedule End-user Engineer Production Schedule. Completion dates

Sales Support Limitorque Engineer Information on Limitorque products

Manuals for DDC-100 Operation:

• LMAIM4019 Direct-to-Host Programming

Guide

• LMAIM1329 Accutronix Installation and

Operation for MX-DDC Field Unit

• LMAIM4029 DDC-100 UEC Field Unit

Manuals Limitorque Engineer

Contractor,

Project Speciﬁcation Engineer

Project Responsibility

P&ID Engineer Contractor

Site Electrical and electronics

Loop Drawings Engineer Contractor

Engineer Contractor

S/I, OEM,

Limitorque

(Modbus) Installation and Operation Manual

• LMAIM4030 DDC-100 UEC Field Unit Installation and Commissioning Manual

• LMAIM4022 DDC-100 UEC Field Unit

Wiring and Startup Guidelines

• Modicon Modbus Protocol Reference Guide

PI-MODBUS-300 Rev. G (available from Modicon)

Provide operational speciﬁcations for all equipment and service providers

Deﬁne which supplier is responsible for each portion of project

Detailed layout and instructions for building site. Information should include actuator tag names, required data points from actuator, ﬁeld unit, and ﬁeld wiring

Detail site electrical requirements, cable type, layout, and locations. Voltages available for equipment

Detail cable routings from Host to each ﬁeld device. This deﬁnes how the network cable is to run throughout the facility

54 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 55

Contractor Tasks

Deliverable From To Comments

Speciﬁcations Engineer Contractor Complete P&IDs for site

Schedule Engineer Contractor Time line complete w/milestones

Project Responsibilities

P&ID Engineer Contractor

Site Electrical

and electronics

Loop Drawings Engineer Contractor

Schedule Contractor Limitorque

Hardware

Manuals Limitorque Contractor

Operational System S.I. Contractor

Documents S.I. Contractor

Schedule Contractor S.I.

Hardware for system development

Actuator Contractor S.I.

Site Preparation Contractor S.I.

Site Preparation Contractor Limitorque

Field Unit Startup Limitorque Contractor

Engineer Contractor

Limitorque,

OEM

Contractor S.I.

Contractor

Deﬁne which supplier is responsible for each portion of project

Detailed layout and instructions for building site. Information should include actuator tag names, required data points from actuator, ﬁeld unit, and ﬁeld wiring

Detail site electrical requirements, cable type, layout, and locations. Voltages available for equipment

Detail cable routings from Host to each ﬁeld device. This deﬁnes how the network cable is to run throughout the facility

Provide material delivery dates for hardware. Schedule Flowserve Limitorque Controls Service Technician for actuator commissioning (when requested according to purchase order)

Provide Motor-Operated Valves, RS-232/485 converters (if supplied), valves, mounting adapters, etc.

Product Bulletins for Actuators:

• LMAIM4019 Direct-to-Host Programming

Guide

• LMAIM1329 Accutronix Installation and

Operation for MX-DDC Field Unit

• LMAIM4029 DDC-100 UEC Field Unit

(Modbus) Installation and Operation Manual

• LMAIM4030 DDC-100 UEC Field Unit Installation and Commissioning Manual

• LMAIM4022 DDC-100 UEC Field Unit

Wiring and Startup Guidelines

• Modicon Modbus Protocol Reference Guide

PI-MODBUS-300 Rev. G (available from Modicon)

Develop and test programming for DCS system

Documentation of program operational characteristics, equipment used, and Operation and Maintenance Manuals for equipment

Provide delivery dates for commissioning control system. Include dates for testing, documentation, and turnover to site personnel

Hardware may include: DDC-100 Field Units, RS-232/485 converters

Availability of DDC-100 Field Unit for testing developed application software

Complete actuator or ﬁeld unit installation. Provide actual (as installed)

Install speciﬁed equipment, cables for power and network communication. Verify all network and power cables are properly routed, terminated, and documented prior to commissioning of DDC-100 Network. The contractor should provide detail on network routing from Host system to each ﬁeld unit. Verify all ﬁeld units are properly grounded

According to purchase order requirements, when scheduled

Limitorque Tasks

Deliverable From To Comments

Speciﬁcations Engineer Limitorque

Schedule Contractor Limitorque

Site Preparation Contractor Limitorque

Operational S.I. Limitorque

Tag List S.I. Limitorque

Sales Support Limitorque Engineer Information on Limitorque products

S.I.

Manuals Limitorque

Hardware Limitorque, Contractor

Field Unit Startup Limitorque Contractor

Engineer

Contractor

Provide speciﬁcation on Motor-Operated Valves, other DDC-100 Field Units (I/O Modules). Provide P&IDs

Provide material delivery dates for hardware. Schedule Flowserve Limitorque Controls Service Technician for actuator commissioning

Install speciﬁed equipment, cables for power, and network communication. Verify all network and power cables are properly routed, terminated, and documented prior to commissioning of DDC-100 Network. The contractor should provide detail on network routing from Host system to each ﬁeld unit. Verify all ﬁeld units are properly grounded

Provide unique ﬁeld unit requirements to Controls Service Technician Requirements prior to start of ﬁeld unit commissioning process. Include: ESD requirements, open/ close service or position control (“move-to”), digital inputs/outputs, analog inputs

Provide a tag list detailing valve tag name to network address. This will allow the Limitorque Controls Service Technician (when requested according to purchase order) to properly address the actuators to the developed Host software

Product Bulletins for Actuators:

• LMAIM4019 Direct-to-Host Programming

Guide

• LMAIM1329 Accutronix Installation and

Operation for MX-DDC Field Unit.

• LMAIM4029 DDC-100 UEC Field Unit

(Modbus) Installation and Operation Manual

• LMAIM4030 DDC-100 UEC Field Unit Installation and Commissioning Manual

• LMAIM4022 DDC-100 UEC Field Unit

Wiring and Startup Guidelines

• Modicon Modbus Protocol Reference Guide

PI-MODBUS-300 Rev. G (available from Modicon)

Provide Motor-Operated Valves, RS-232/485 converters (if supplied), OEM valves, mounting adapters, etc.

According to purchase order requirements, when scheduled

56 DDC-100 Direct-to-Host Programming Guide FCD LMAIM4019-00 FCD LMAIM4019-00 DDC-100 Direct-to-Host Programming Guide 57

Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide speciﬁc data and warnings for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the speciﬁc application.

While the information and speciﬁcations contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certiﬁed or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve is continually improving and upgrading its product design, the speciﬁcations, dimensions and information contained herein are subject to change without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or ofﬁces.

For more information about Flowserve Corporation, visit www.ﬂowserve.com or call USA 1-800-225-6989.

Limitorque 5114 Woodall Road, P.O. Box 11318 Lynchburg, VA 24506-1318 Phone: 434-528-4400 Facsimile: 434-845-9736 www.limitorque.com

Limitorque India, Ltd. 15/4, Mile Stone Mathura Road Faridabad 121002 India Phone: 91-129-2276586

Facsimile: 91-129-2277135 Limitorque Abex Road Newbury Berkshire, RG14 5EY England Phone: 44-1-635-46999 Facsimile: 44-1-635-36034

Flowserve Australia, Pty. Ltd.

14 Dalmore Drive

Scoresby, Victoria 3179

Australia

Phone: 61 3 9759 3300

Facsimile: 61 3 9759 3301

Limitorque Nippon Gear Co., Ltd. Asahi-Seimei Bldg. 4th Floor 1-11-11 Kita-Saiwai, Nishi-Ku Yokohama-Shi, (220-0004) Japan

Limitorque Asia, Pte., Ltd.

12, Tuas Avenue 20

Singapore 638824

Phone: 65-6868-4628

Facsimile: 65-6862-4940 Phone: 81-45-326-2065 Facsimile: 81-45-320-5962

(Replaces 435-23009)

Flowserve DDC-100 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table 3.1 – Field Unit Communication Parameters

Table 3.2 – Modbus Function Codes Supported

Table 3.3 – DDC-100 Coil Assignments, Modbus Function Code 01 Usage for Digital Outputs

Table 3.6 – DDC-100 Coil Assignments Modbus Function Code 05 Usage for Digital Outputs

Table 3.7 – Modbus 06 Command and Field Unit Holding Register 40001

Table 3.8 – Diagnostic Codes Supported by the DDC-100 Field Unit

Figure 4.1 – DDC-100 Redundant Loop Network

Figure 4.2 – DDC-100 Single-Ended Loop Network

Figure 4.3 – DDC-100 Single-Line Multi-Drop Network

Table 4.2 – Average Network Scan Time (seconds)

Table 4.1 – Average Field Unit Response Time

Table 5.2 – Steered Converter Assembly (P/N 22300-7591)

Table 5.3 – Self-Steering Converter Assembly (P/N 22300-7601)

Figure 5.1 – RS-232/RS-485 Converter Dimensions and Rack Mount Kit

Figure 5.2 – RS-232/RS-485 Cable Diagram

Figure 5.3 – Front and Back Panels of Steered Converter

Table 5.4 – RS-232/RS-485 Converter (P/N 61-825-0966-4) DIP Switch Functions

Table 5.6 – RS-232/RS-485 Converter (P/N 61-825-0966-4) RS-485 Connector

Table 5.7 – RS-232/RS-485 Converter (P/N 61-825-0966-4) Jumpers

Figure 5.4 – Front and Back Panels of Self-Steering Converter

Table 5.8 – RS-232/RS-485 Converter (P/N 61-825-1032-4) RS-232 Connector

Table 5.9 – RS-232/RS-485 Converter (P/N 61-825-1032-4) RS-485 Connector

Table 6.1 – Sample Tag Table for Direct-to-Host applications