CAL Controls CALCOMMS 3300 Use and care manual
COMMERCIAL IN CONFIDENCE
CAL 3300/9300/9400/9500(P)
MODBUS RTU
COMMUNICATIONS GUIDE
7th Septem er 2000
ISSUE 1.10
Doc:33034 Iss:002
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Page 1
DESCRIPTION
This document describes the interaction between a CAL Controller with the communications option
fitted and a C/ LC attached to the bus and acting in a command mode.
There are fundamental limitations placed on the interactions. These arise from the intrinsic properties
of the CAL controllers, with just three control buttons and a multi-level menu with increment or
decrement value change process.
The standalone CAL controllers currently perform a verification on each change to ensure that illegal
values (e.g. ones outside the limit range for a particular thermocouple, etc.) are not accepted .The C
application needs to replicate the verification checks that the CAL controllers would perform before
transmitting the new data out over the bus to the instrument. The CAL controllers assume that the
values they receive have been checked against limits and are valid - no further verification is carried
out. Upon receipt of the new values and an exit program mode sequence the CAL controllers write the
new values to memory and then restart.
_Copyright Cal Controls Ltd 1999. All rights strictly reserved. No part of this documentation shall be
reproduced ,stored in a retrieval system, or copied in any form, without prior written permission from
Cal Controls Ltd. Every effort has been taken to ensure the accuracy of this specification. However due
to our policy of continuous development to improve our products, this could without notice, result in
amendments or omissions to this document. Neither is any liability assumed for damage, injury, loss,
or expenses resulting from the use of this document.
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Page 2
1. MEMORY MAP OF PARAMETERS
WARNING:- As with any computer system writing to any unauthorised memory address will
inevitably cause malfunction and may put the instrument in an indeterminate or dangerous state. It is
the users responsibility to ensure correct use.
The instruments uses a 8051 type processor. This has two types of RAM: the internal 256 bytes and
the external 256 bytes, data is also stored in EE ROM (non-volatile ram). Each data area requires a
different access method internally.
Data can be accessed as either one byte or a two byte word - the word need not necessarily lie on an
even address boundary. To simplify ModBus messages the unit decodes the MSB of the ModBus
address to select which type of memory to access - thus all memory looks the same to the end user.
Decoding is as follows:
bit 7 bit 6 bit 5 bit 4 bit 3 bit 2 bit 1 bit 0
always 0 always 0 always 0 1=security always 0 1=NVram 1=external 1=one byte
so that the following addresses specify the given memory areas:
• 00xxH references internal memory - two bytes wide
• 01xxH references internal memory - one byte wide
• 02xxH references external memory - two bytes wide
• 03xxH references external memory - one byte wide
• 04xxH references NV memory - two bytes wide
• 05xxH references NV memory - one byte wide
note that messages with both bits 1 and 2 set are misleading and should not occur, however, they will
be interpreted as if bit 2 was 0. Bit 4 is used to indicate reserved messages - see the section Security
Messages below.
Two types of bit value may exist:
• those which can be set and cleared as a single operation (i.e. directly addressable) are
defined as type bit.
• those which must be set or cleared by reading a byte, masking the bit, then writing the
byte.
Bit addresses are represented by both the absolute hex address and also by bit number (in decimal) if
the bit is directly addressable. Note that, in this document, the bit number is one based (1..128) which
matches the usual representation of ModBus.
T e byte and word addresses given are t e absolute HEX locations in t e instrument.
Depending on t e type of ModBus driver being used, t ese may need to be converted to a
decimal address, plus 1, since some ModBus drivers subtract 1 from t e address given. Thus to
access the Baud Rate (03D6) a ModBus driver would need decimal address 983 (982 + 1).
Shaded sections denote contiguous address space which may be read and written as multiple
registers if the remote software can handle this. NOTE t at due to space limitations t e current
implementation does not allow multiple address access - only one word can be accessed per
message.
To facilitate easy reading, the following tables are listed in address order, not the order on the menus.
Extreme care must be taken to write only to t ose locations indicated. Writing to any ot er
locations WILL corrupt t e instrument, but t e effects may not necessarily be immediately
noticed.
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1.1 Internal data formats
The instrument stores data in a variety of ways to allow a full range of values to be held in the minimum
space possible. Most are represented by a multiple of the displayed value - this is given as a scale
factor in the table below: for instance, temperatures are stored in 10ths of a degree, so a displayed
value of 123.4 degrees is stored as 1234 - this is shown in the tables as temp * 10. Some time values
are stored in 40ms units so a time of 1 second would be stored as 25. A few parameters - mainly the
times - have different scale factors and offsets depending on their current value - these are detailed
individually.
arameters are incremented/decremented by fixed step sizes depending on their current value within
limits which may change depending on the current value of other parameters. Many parameters
increment and decrement in the same manner - this is referred to in the tables as normal inc/dec - in
these cases parameters move in 0.1 steps between —9.9 and 9.9, otherwise in steps of 1. Note that
when incrementing or decrementing, the internal storage format must be taken into account and also
whether the display is in hi-res mode - values sent to the instrument must match the current mode.
Note also that in the 9500 instrument parameters marked with [LIN] are stored in degrees*10 when the
selected input is a thermocouple or RTD and units of 1 when the selected input is linear. Also note that
while linear input is selected the display of values on the instrument is effected by the setting in DEC
not Disp.
The instrument provides no error checking on values transmitted to it - the user must ensure that new
values are checked for consistency before uploading.
1.2 Variables not on menu structure
Parameter
Name
Size Address
( ex)
R/W ModBus
Function
read/write
Internal Storage, Step rate in
Internal units
Comments
S 1 2 007F RW 3/6 Degrees * 10 [LIN]
step 1 from LoSc to HiSc
The setpoint required. See 1.2.1
below regarding initialising a new
instrument
Setpoint
safety check
1 0125 RW 3/6 see note 1.2.1 below for correct
usage of this byte
Temperature 2 001C R 3/6 Degrees * 10 [LIN] stored as 10ths of deg C
security byte 1 0300 W 6 no scaling see 2.3 for security messages
Ramp Byte 1 0305 R 3 no scaling see 1.2.2 below for bit meanings
Display Byte 1 0306 R 3 no scaling see 1.2.3 below for interpretation
Display State 2 0205 R 3 no scaling a word read enables Ramp byte
and Display Byte to be read with a
single message
Model
(Type of inst
and output
configuration)
2 04FC R 3 0X01 33/9300 RLY / SSD
0X02 33/9300 SSD / SSD
0X03 33/9300 RLY / RLY
0X07 9400 RLY / SSD
0X08 9400 SSD / SSD
0X09 9400 RLY / RLY
0x10 9500 SSD / RLY / RLY
0x11 9500 SSD / SSD / RLY
0x12 9500 RLY / RLY / RLY
0x13 9500 ANLG / RLY / RLY
0x14 9500 ANLG / SSD / RLY
Type of instrument and output
configuration are determined by
the hardware, but can be read
from the address 04FC
The Ramp and Display bytes have been kept together so that a single word read at address 0x0205
can be used to obtain full information about the state of the instrument display.
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Page 4
1.2.1 Initialising t e Setpoint
The instrument is provided with a safety lock to prevent it from controlling until the setpoint has been
set. This lock is automatically released the first time that the setpoint is changed from the instrument
front panel. If it is required to initialise a new instrument (or after the parameters have been reset), this
lock may be released remotely by performing the following sequence:
tempbyte = (read byte at ModBus address 0125 hex)
tempbyte = tempbyte OR 0x02 {i.e. set bit 1}
(write tempbyte back to ModBus address 0125 hex)
Note that this sequence is only required to unlock the instrument from its reset state - it is not
necessary to perform this sequence each time the setpoint is changed. The other bits within this byte
are used internally and must not be modified.
1.2.2 Ramp Byte
The Ramp Byte holds bits which show what stage of a ramp/soak sequence is currently active:
• bit 1 set = in ramp phase, display periodically flashing S r
• bit 2 set = in soak phase, display periodically flashing Soak
• bit 3 set = sequence finished, control dormant, display flashes Stop
• bit 6 set = Holdback LED on front display lit (9500P only)
note that these bits are mutually exclusive (except the holdback bit), and the flashing display is of lower
priority than the displays recorded by the Display Byte. If no bit is set, the instrument is not in a
ramp/soak sequence. If the unit has finished a ramp but no soak time is specified (SOAK= - - ) bit 2
will remain set.
The other bits in the Ramp Byte are used internally by the instrument. T e Ramp Byte must not be
written to - unpredictable and possibly dangerous instrument be aviour will result.
1.2.3 Display Byte
The Display Byte records the message currently being shown on the instrument display, and also
mirrors the state of the S LED s - note that although these may be read by a remote program, their
values may change rapidly in real time. Due to the time lag in processing communications messages it
may not be possible to exactly mimic the display on a remote screen - particularly for short cycle times.
The hi nibble conveys the following meanings:
• Bit 7 set = S 2 LED lit
• Bit 6 set = S 1 LED lit
• Bit 5 set = add FAIL display to other indications
• Bit 4 set = S 3 LED lit (9500 only)
The low nibble of the Display Byte indicates the current alternating message being displayed, thus
after t e top 2 bits are masked off, the following values indicate the display message:
0x01 = ARK / temp
0x02 = -AL- / temp
0x03 = TUNE / temp
0x23 = TUNE / FAIL
0x04 = TUNE / ATS / temp
0x05 = HAND / heat power ratio
0x25 = HAND / FAIL
0x26 = IN T / FAIL
0x27 = DATA / FAIL
These messages take display precedence over any others. If one of the Display Byte messages is
indicated, the remote program must ignore the state of the Ramp Byte.
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Page 5
1.3 Level C - parameters in address order
Parameter
Name
Size Address
( ex)
R/W ModBus
Function
read/write
Internal Storage, Step rate in
Internal units
Comments
Addr 1 03D5 RW 3/6 0..255 valid range 1..247
Baud 1 03D6 RW 3/6 0=1200, 1=2400, 2=4800, 3=9600,
4=19200
Data 1 03D7 RW 3/6 0=18n1, 2=18e1, 3=18o1,
Dbg 1 03D8 RW 3/6 0=off, 1=on
note that all changes to the communications level parameters take effect immediately on leaving the
menu, or on receipt of the exit program mode command. The dbg feature may be set on or off. When
on, the right-most digit will flash 3 horizontal segments on receipt of a character when a
communications board is fitted, the left-most digit will flash on transmission of a character.
1.4 Level 1 - parameters in address order
Parameter
Name
Size Address
( ex)
R/W ModBus
Function
read/write
Internal Storage, Step rate in Internal units,
Limits
Comments
Set.2 2 0081 RW 3/6 Degrees * 10 [LIN]
Step 0.1 or 1 depending on disp selection
min=LoSc, max=HiSc
Ofst 2 0083 RW 3/6 Degrees * 10 [LIN]
normal inc/dec
see separate details for limits
Band 2 0085 RW 3/6 Degrees * 10 [LIN]
normal inc/dec
min=0.1 max=25% of Sensor Maximum
9500 max is
100% of sensor
maximum
Bnd.2 2 0087 RW 3/6 Degrees * 10 [LIN]
normal inc/dec
see separate details for limits
Tune 1 0189 RW 3/6 0=off, 1=on, 2=park, 3=at Setpoint
Dac 1 018A RW 3/6 stored as value*2 so 0.5 is stored as 1
step by 0.5
Min=0.5 max=5.0
Int.t 1 018B RW 3/6 intt * 10 up 10.0, then intt+90
normal inc/dec
0=off min=0.1, max=60
Der.t 1 018C RW 3/6 1 — 200 in 1 sec steps
Cyc.t 1 018D RW 3/6 Cyct * 10 up 10.0, then Cyct+90
normal inc/dec
0=off min=0.1, max=81
Cyc.2 1 018E RW 3/6 Cyc2 * 10 up 10.0, then Cyc2+90
normal inc/dec
0=off min=0.1, max=81
S .lk bit 0028 RW 1/5 0=off, 1=on
S rr 2 02D0 RW 3/6 Stored as S rr
if <100 step by 1, if <1000 step by 5 else step by
10
min=0 max=9990
9500 display
effected by DEC
when LIN input
selected
Soak 2 02D2 RW 3/6 0xFF00 = - - , 0=off, otherwise Soak * 10
Step by 1 up to 120, then 5 up to 300 then by 10
min = 1, max=1440
S rn 1 03D4 RW 3/6 0=off, 1=on, 2=hold 9500P See Level
section for notes
on starting a
program
COMMERCIAL IN CONFIDENCE
Page 6
1.5 Level 2 - parameters in address order
Parameter
Name
Size Address
( ex)
R/W ModBus
Function
read/write
Internal Storage, Step rate in
Internal units, Limits
Comments
S 1.
S 1_ontime
S 1_proptime
2
2
0062
0078
R
R
3
3
not stored must be computed as
S 1_ontime/S 1_proptime
*100%
Disp bit 002A RW 1/5 0=low res, 1= high res
Hand 1 018F RW 3/6 No scaling
step by 1
min 0=off, max=100
L.1 1 0190 RW 3/6 No scaling
step by 1
min=0, max=100
L.2 1 0191 RW 3/6 No scaling
step by 1
min=0, max=100
S 2.A 1 0192 RW 3/6 0=none, 1=dvhi, 2=dvlo, 3=band,
4=fshi, 5=fslo, 6=cool
9500P 7=EO
S 2.b 1 0193 RW 3/6 0=none, 1=ltch, 2=hold, 3=ltho,
4=nlin
Hi.SC 2 0094 RW 3/6 HiSc * 10 [LIN]
step by 0.1 or 1
min=Sensor Min, max=Sensor Max
Lo.SC 2 0096 RW 3/6 LoSc * 10 [LIN]
step by 0.1 or 1
min=Sensor Min, max=Sensor Max
Inpt 1 0198 RW 3/6 0=none, 1=Tcb, 2=Tce, 3=Tcj,
4=Tck, 5=Tcl, 6= Tcn, 7=TcR,
8=Tcs, 9=Tct, 10=RTD, 11=lin1
12=lin2, 13=lin3, 14=lin4, 15=lin5
9500
11=lin
12-15 unused
Unit 1 0199 RW 3/6 0=none, 1=C, 2=F, 3=bar, 4= SI,
5= h, 6=Rh, 7=set
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Page 7
1.6 Level 3 - parameters in address order
Parameter
Name
Size Address
( ex)
R/W ModBus
Function
read/write
Internal Storage, Step rate in
Internal units, Limits
Comments
S 1.d 1 019D R 3/6 0=none, 1=rly, 2=ssd, 3=rly1,
4=rly2
5=ssd1(ssd2)
9500
0=none 1,3,4,10=ssd
2,5,6,8=rly 7,9=anlg
S 2.d N/A N/A N/A N/A Not stored Inverse of S 1.d
Burn 1 019E RW 3/6 0=upsc, 1=dnsc, 2=1u2d, 3=1d2u
Rev.d 1 019F RW 3/6 0=1r2d, 1=1d2d, 2=1r2r, 3=1d2r
Rev.l 1 01A0 RW 3/6 0=1n2n, 2=1l2n, 3=1n2l, 4=1l2l
Span 2 00A1 RW 3/6 Span * 10 [LIN]
normal inc/dec
min = -0.25 * Sensor Min
max = 0.25 * Sensor Max
Zero 2 00A3 RW 3/6 Zero * 10 [LIN]
normal inc/dec
min = -0.25 * Sensor Min
max = 0.25 * Sensor Max
Chek bit 0026 RW 1/5 0=off, 1=on
Read (var) 2 computed from 2 vars (below)
Read(hi) - Read(lo) with
degC to decF if required (if
unit=1)
Read (hi) 2 007A R 3 Read(hi) * 10 [LIN]
Read (lo) 2 007C R 3 Read(lo) * 10 [LIN]
Data (Ct A) 2 0432 R 3 CtA * 25
Data (Ct B) 2 0434 R 3 CtB * 25
Data (Ct 1) 2 0436 R 3 Ct1 * 25
Data (Ct 2) 2 0438 R 3 Ct2 * 25
Data (Ct 3) 2 043A R 3 Ct3 * 25
Data (Ct 4) 2 043C R 3 Ct4 * 25
Data (Os 1) 2 043E R 3 Os1 * 10 [LIN]
Data (us) 2 0440 R 3 Us * 10 [LIN]
Data (Os 2) 2 0442 R 3 Os2 * 10 [LIN]
Ver
(S/W ver)
2 04FD R 3 0xFFFF/ 0x01 means ver 391
0x02 means ver 392
0x03 means ver 941
0x04 means ver 951
0X05 means ver 952
3300/9300 ver 1
3300/9300 ver2
9400 ver 1
9500 ver 1
9500 ver 2
Rset bit 0027 RW 1/5 0=none, 1=all
1.7 Level 4 - parameters in address order
Parameter
Name
Size Address
( ex)
R/W ModBus
Function
read/write
Internal Storage, Step rate in
Internal units, Limits
Comments
Der.S 1 019A RW 3/6 Ders * 10
Dis.S 1 019B RW 3/6 0=dir, then 1..32
step by 1
min=0, max=32
Lock 1 019C RW 3/6 0 = none, 1=lev3, 2=lev2, 3=all
rog bit 002D 1/5 0 = auto, 1=stay
No.Al bit 002E RW 1/5 0 = off, 1=on
COMMERCIAL IN CONFIDENCE
Page 8
1.8 Level A – parameters in address order (9500 only)
Parameter
Name
Size Address
( ex)
R/W ModBus
Function
read/write
Internal Storage, Step rate in
Internal units, Limits
Comments
An.Hi 2 02D9 RW 3/6 AnHi
Step=1
min=-1999, max=9999
An.Lo 2 02DB RW 3/6 AnLo
Step=1
min=-1999, max=9999
Hi.In 2 02DD RW 3/6 HiIn * 10
step=0.1
min=0.1, max 50.0
HiIn must always be 0.1 above
the LoIn setting
Lo.In 2 02DF RW 3/6 LoIn * 10
step=0.1
min=0.0, max 49.9
DEC 1 03E1 RW 3/6 0=0000, 1=000.0, 2=00.00 Decp over-rides the Disp setting
in level 2 while linear input
selected
S 3.A 1 03E2 RW 3/6 0=none, 1=dvhi, 2=dvlo, 3=band,
4=fshi, 5=fslo
9500P 7=EO
S 3.B 1 03E3 RW 3/6 0=none, 1=ltch, 2=hold, 3=ltho
Brn.3 1 03E4 RW 3/6 0=upsc, 1=dnsc
Rev.3 1 03E5 RW 3/6 0=3d, 1=3r
Set.3 2 02E8 RW 3/6 Degrees * 10 [LIN]
step=0.1
min=0.0, max=2500
When LIN sensor selected
max=9999
Hys.3 2 02EA RW 3/6 Hys3 * 10 [LIN]
step=0.1
min=0.1, max=100% of HiSc
Note: The level A menu is only available in the 9500 instrument.
1.9 Level P – parameters in address order (9500P only)
Parameter
Name
Size Address
( ex)
R/W ModBus
Function
read/write
Internal Storage, Step rate in
Internal units, Limits
Comments
Max rog 1 033A R3 Maximum rogram Number Generated by the instrument, do
not write to this location.
rog 1 036C RW 3/6 rogram Number
min=1, max=Max rog
To start a program write the
number of the program to run
and then set the value of
Sprn(Level 1) to ON or HOLD
Note: the program will not start
until after the exit program mode
Note: The level menu is only available in the 9500 instrument.
Note: The other elements of the programmer (Level ) menu are unavailable from the communications
interface.
COMMERCIAL IN CONFIDENCE
Page 9
2. ACTIONS REQUIRED TO COMMUNICATE WITH THE
INSTRUMENTS
These versions of the instruments have ModBus functions codes 1,3,5,6 and 16 implemented. Note
that although function code 16 (write multiple registers) is recognised, this cannot deal with more than
a single 2 byte register write and will return an error if more registers are attempted. There is no facility
to read multiple registers, nor to read or write multiple bits.
2.1 Notes
• Un-implemented function codes do not yet return error code 01.
• Function code 15 (read multiple registers) is not implemented.
2.2 Implementation restrictions
A number of restrictions are made :
• Multiple register reads are not implemented, since the opportunity to use them is very
limited and there is not sufficient memory to buffer long messages.
• Multiple bit reads and writes are not implemented, since we do not have any consecutive
bits available to the user.
2.3 Security Messages
To allow communications to safely manipulate t e instrument a number of security messages
ave been implemented. CAL Controls see t ese as important safety features, w ic offer a
number of advantages, especially w en configuring a safety critical application.
T e messages to enter program mode only ave to be sent once to access t e Internal
parameters of t e instrument and t en any number of adjustments can be made. T e advantage
t is offers is t at sending t e enter program mode message, causes t e pus buttons on t e
instrument to be locked out. T is feature prevents potentially dangerous conditions arising
from simultaneous adjustment of t e instrument locally w ilst adjustments are being sent over
t e communications link.
T e messages to exit program mode causes t e instrument to write back any internal
parameter c anges to t e NVram, and t en use t ese settings. T is means t at any c anges
made will not take effect until t e instrument as received t e exit program mode message. T e
advantage t is offers is t at all adjustments take place at t e same time. If for instance you are
configuring alarm functions you will not get false alarms due to setting t e alarm mode before a
valid alarm set point as been programmed, also all PID terms are implemented toget er,
w ereas separate adjustment of PID functions may cause greater control instability.
To prevent inadvertent changes a security byte must be set immediately before any security message
is transmitted - this byte is automatically reset after each message.
Each security message is numbered 1 to 6, this number must be set into the security byte immediately
prior to the message, if the security byte does not match the security message number, the message
will be ignored and no response will be issued. Messages 1 to 4 are implemented but currently have no
direct use.
Note: T e 9500 does not require t e security byte messages to be sent to enter and exit
program mode, t e messages not required are noted below.
The correct sequence to set new parameters into the instrument is as follows:
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