Sierra Manual

SIERRA CMC TROUBLESHOOTING AND REMOTE COMMUNICATIONS REFERENCE MANUAL
(Part No. 80441801)
INGERSOLL-RAND AIR COMPRESSORS
CMC TECHNICAL REFERENCE MANUAL
Copyright Notice
Copyright 2004 Ingersoll-Rand Company THIS MANUAL IS SOLD "AS IS" AND WITHOUT ANY EXPRESSED OR IMPLIED WARRANTIES WHATSOEVER. Printing Date: 15 December 2004 Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air applications. Ingersoll-Rand does not approve specialized equipment for breathing air applications and assumes no responsibility or liability for compressors used for breathing air service.
80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004
Table of Contents
References ___________________________________________________________2 General - CMC Panel ___________________________________________________3 Protection and Monitoring ______________________________________________4
Analog Functions __________________________________________________________ 4 Digital Functions __________________________________________________________ 5
Troubleshooting ______________________________________________________7
Troubleshooting Example ___________________________________________________ 8 Input/Output (I/O) System ___________________________________________________ 9 Control Power System (CPS) _______________________________________________ 27 Controller Problems_______________________________________________________ 30
Communication ______________________________________________________32
Human Machine Interface (HMI) Systems _____________________________________ 32 Direct CMC Communications with RS422/485__________________________________ 32 The CMC-MODBUS Interface________________________________________________ 33 The CMC-DF1 Interface ____________________________________________________ 52
Documentation_______________________________________________________79 System Information ___________________________________________________79

Status Codes ____________________________________________________________ 79 Base Control Module (BCM) ________________________________________________ 81 Operator User Interface Module (OUI) ________________________________________ 84 Universal Communication Module (UCM) Optional _____________________________ 88
Glossary _____________________________________________________________1
References
The following references were used in creating this document. All of this documentation is recommended for a more detailed understanding of specific control modes and control panel functions. NEMA STANDARDS PUBLICATION NO. 250, Enclosures for Electrical Equipment (1000 Volts Maximum), Revision 2, May 1988 NFPA 496 Standard for Purged and Pressurized Enclosures for Electrical Equipment, 1986 Edition Doebelin, Ernest O., Control System Principles and Design, John Wiley & Sons, 1985 Rowland, James R., Linear Control Systems Modeling, Analysis, and Design, John Wiley & Sons, 1986 Deshpande, Pradeep B. and Ash, Raymond H., Computer Process Control With Advanced Control Applications, 2nd Edition, Instrument Society of America, 1988 Harrison, Howard L. and Bollinger, John G., Introduction to Automatic Controls, Second Edition, Harper & Row, 1969
General - CMC Panel

The CMC panel is the microprocessor-based control and monitoring system for Sierra. The CMC handles compressor control and monitoring functions; as well as, control of auxiliary equipment such as the main motor starter, condensate solenoid valve and the load solenoid valve. The CMC panel has a custom computer board called the Base Control Module (BCM). This board has a microcontroller and memory chips that tell the rest of the panel what to do for the various input pressures and temperatures. All hardware for data analysis, number of input and output (I/O) points and system memory are optimally selected for accurately controlling and protecting Sierra compressors. Features of the CMC system are:

Ease of use ... only twelve buttons to push on the operator OUI! Multiple function, 240 x 128 pixel graphic LCD to display data, operating status and basic operator instructions. First-out indication and event log to help determine the root cause of a compressor trip. Base Control Module CPU running at 25Mhz. Base Control Module, Operator User Interface and Universal Communication Modules capable of serial communication at 38,400 baud Optional port for communicating to the Air System Controller (ASC), Air System Manager (ASM) or other Distributed Control Systems (DCS) via MODBUS protocol.
NOTE For the purpose of consistency and clarity, all of the descriptions and examples that follow refer to "air" for the more generic "gas". Any gas compressed by a Sierra compressor would also apply.
Protection and Monitoring

Each CMC base module has Twenty-three analog inputs, sixteen digital inputs, four analog outputs and sixteen digital outputs for control, protection and monitoring. These input functions provide the CMC with information about the compressor. The CMC board uses the output functions to communicate to the user and perform actions like starting the compressor. All of these inputs and outputs are required to interface physical actions to and from the electronics.
Analog Functions
An analog function is one in which an electrical signal represents a specific pressure or temperature. As these inputs and outputs fluctuate, the electrical signal to and from the microprocessor board also fluctuates proportionally to the amount of change.
Analog Inputs
Twenty-one grounded and two floating analog inputs are used for protection, monitoring and control. Each input used for protecting the compressor can be programmed for alarm and trip indication. Each of these functions is pre-programmed with the function title, engineering units, range, alarm and trip values, so no configuration is required upon receipt by the customer. The CMC uses pressure transmitters to measure pressure, resistance temperature detectors (RTD), thermistors and transmitters to measure temperature. The CMC logic used for the protective alarm and trip functions is as follows: if the actual value of the input is greater than or equal to the alarm or trip value, indicate the condition. This logic is used for all inputs except, low oil pressure where the logic is reversed.
Analog Outputs
The Sierra CMC controller does not use any analog outputs.
Analog Input (AI) Fail

If the value of the analog input drops below 2.5mA (low) or exceeds 20.5mA (high) its value in engineering units will not be displayed. When the CMC detects an analog value out of range it will indicate that condition on the page that normally displays the engineering units reading. In the example at the right, Package System Page 4APT Failed Discharge Pressure, 4APT, has failed as indicate by the OUI System folder and Status Bar. Analog input failures are treated as Trips.
The 4APT failure is also listed on the Event Log. Assuming in our example 4APT failed low, the Event Log entry would indicate the failure was Low. High failures will be shown in a similar manner, with the word High replacing Low. See the Troubleshooting section of this manual to resolve irregular analog input values.
Event Log 4APT Failed Low
Digital Functions
A digital function is one in which the presence of an electrical signal indicates ON or YES, and the lack of that signal represents OFF or NO. This is analogous to a light switch that has only two states, ON or OFF. The term "discrete" is also used instead of digital in many instances. The term that will be used throughout this documentation shall be digital.
Digital Inputs
The sixteen digital inputs provide status of motor overloads, remote start/stop, remote load, auxiliary inputs and emergency stop. Any of these inputs can be configured as an alarm or trip. All inputs operate on 24 VDC power.
Digital Outputs
The sixteen digital outputs are used by the CMC to energize the main starter contacts, indicate that an alarm or trip condition exists, activate the condensate and load solenoid valves, indicate that the compressor is stopped in auto restart and to sound the horn. Outputs can operate on 120 VAC, 50/60 Hz, single-phase power or 24 VDC power.
Alarm and Trip Settings

These values determine when the controller will indicate an alarm or trip condition.
WARNING
Setting Trip values outside the range specified in the Operators/Instruction Manual can result in compressor damage.
Troubleshooting
The following procedures provide direction on troubleshooting the CMC System, control panel, and associated instrumentation. Faults are either Event Logged, which means the fault is displayed in the INFO Folder on the OUI, or Non-Event Logged. The distinction helps to expedite the troubleshooting process. When a control system fault is suspected, the following diagram (figure 1) is used to categorize the fault. The section following the diagram breaks each category down into specific items, which can cause a particular fault.
Figure 1: Troubleshooting Tree
Troubleshooting Example
The following example will serve as a guide to follow when troubleshooting specific problems.
SYSTEM INFO
Problem Indication: Plant air pressure is low and the CMC OUI is found as shown. Probable Cause Determination: 1.
1 2 3 4 5 6 7
SETTINGS
SERVICE
Time 09:18:44 09:18:43 09:18:34 09:08:43 08:58:23 08:24:01 08:23:12 Trip Remote Date 0720 0720 0720 0720 0720 0720 0720 2/3
Event Name Low Oil Press Trip Low Oil Press Alarm Reset key pressed Low Oil Press Trip Low Oil Press Alarm Load key pressed Start key pressed
Not Ready
The machine Tripped on Low Oil Pressure, which means the oil pressure, was below the Oil Pressure Trip Value. Figure 2 leads to the assumption that the problem is either compressor or I/O related, because the fault is Event Logged. There are two most likely causes for this event. a) Actual oil pressure is low. i) The oil pump is found to be running and installation of a calibrated pressure sensor shows the actual oil pressure to be above the Oil Pressure Trip Value. Therefore, the mechanical system is operating correctly. The oil pressure value displayed on Page 3 of the System Folder shows the oil pressure to be below the test sensor reading and erratic. Additionally, all other analog input readings are normal and not erratic. Therefore, the problem can be isolated to the oil pressure, analog input circuit. The Pressure Monitoring System (PMS) troubleshooting table, found in the following section The Pressure Monitoring System identifies the probable cause for an erratic reading as a loose wire/terminal/connector and specifies Troubleshooting Procedure PMS #1 and 2 as the appropriate procedures.
b) The value read by the CMC is incorrect. i)
ii)
Trouble Procedure Execution: Step 1 of PMS #1 requires disconnecting of the pressure transducer (PT) wires at the terminal strip. When this step is performed, one of the connections is found to be intermittent. When the poor connection is corrected, the erratic reading on the OUI becomes solid.
Input/Output (I/O) System

Temperature Monitoring System (TMS)
Description: An RTD (Resistance Temperature Detector-2 Wire) with external transmitter is used by the CMC for temperature monitoring. An RTD resistance (ohmic value) varies with temperature. A transmitter for monitoring by the CMC analog input channel converts the resistance to a 4-20 mA signal. Component specification: Probe: 100 ohm Platinum resistance at 32 F (0C) with Temperature Coefficient Rating (TCR) of 0.00385 Ohm/Ohm/Deg C The transmitter is mounted in the control panel enclosure. The transmitter is supplied 24 VDC and outputs 4-20mA over a fixed range of 0-500F (-17.7 to +260C).
Transmitter:
Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem High OUI readout Probable Cause Troubleshooting Procedure TMS #4 TMS #3 TMS #2 TMS #3 TMS #3 TMS #2 TMS #3 TMS #4 TMS #2 TMS #3 TMS #3 TMS #2, 3 TMS #1, 2, 3, 4
High resistance connection Transmitter not calibrated RTD failure Transmitter failure Low OUI readout Transmitter failure RTD failure Transmitter not calibrated Erratic OUI readout Loose terminal connection RTD internal wire fault Transmitter failure Incorrect OUI readout Transmitter not calibrated RTD or transmitter failure Any
10

TMS #1
Checking for Power to the Temperature Transmitter
1. Disconnect the wires at terminals #1 and #2 on the transmitter and connect a voltmeter to these wires. 2. With control power on, there should be approximately 24 VDC present at the terminals. 3. If approximately 24 VDC is not present, see the section titled Control Power System.
BCM
J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23
Pin 25 Pin 1
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
VDC
mA
123 4
VAC
mA COM V RTD Temperature transmitter

Checking for a Faulty RTD 1. Turn control power off. 2. Check ohms versus temperature. Use an Ohmmeter and the following tables to determine if the RTD is faulty. Vary the temperature to the RTD and check the ohms around the normal operating range. TMS #2
11
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
VDC
mA
VAC
mA COM V
Thermometer RTD 32 DEGF
Ice water
12
Degrees Fahrenheit versus Ohms value chart for 100 OHM Platinum RTD
F 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 0 93.01 95.20 97.38 99.56 101.70 103.90 106.10 108.20 110.40 112.50 114.70 116.80 119.00 121.10 123.20 125.40 127.50 129.60 131.70 133.90 136.00 138.10 140.20 142.30 144.40 146.50 148.60 150.70 152.70 154.80 156.90 159.00 161.00 163.10 165.20 167.20 169.30 171.30 173.40 175.40 177.50 179.50 181.50 183.60 185.60 187.60 189.70 191.70 193.70 195.70 197.70 1 93.22 95.42 97.60 99.78 102.00 104.10 106.30 108.40 110.60 112.70 114.90 117.00 119.20 121.30 123.40 125.60 127.70 129.80 132.00 134.10 136.20 138.30 140.40 142.50 144.60 146.70 148.80 150.90 153.00 155.00 157.10 159.20 161.30 163.30 165.40 167.40 169.50 171.50 173.60 175.60 177.70 179.70 181.80 183.80 185.80 187.80 189.90 191.90 193.90 195.90 197.90 2 93.44 95.63 97.82 100.00 102.20 104.30 106.50 108.70 110.80 113.00 115.10 117.30 119.40 121.50 123.60 125.80 127.90 130.00 132.20 134.30 136.40 138.50 140.60 142.70 144.80 146.90 149.00 151.10 153.20 155.20 157.30 159.40 161.50 163.50 165.60 167.60 169.70 171.80 173.80 175.80 177.90 179.90 182.00 184.00 186.00 188.00 190.10 192.10 194.10 196.10 198.10 3 93.66 95.85 98.04 100.20 102.40 104.60 106.70 108.90 111.00 113.20 115.30 117.50 119.60 121.70 123.90 126.00 128.10 130.30 132.40 134.50 136.60 138.70 140.80 142.90 145.00 147.10 149.20 151.30 153.40 155.40 157.50 159.60 161.70 163.70 165.80 167.80 169.90 172.00 174.00 176.00 178.10 180.10 182.20 184.20 186.20 188.20 190.30 192.30 194.30 196.30 198.30 4 93.88 96.07 98.26 100.40 102.60 104.80 106.90 109.10 111.20 113.40 115.50 117.70 119.80 122.00 124.10 126.20 128.30 130.50 132.60 134.70 136.80 138.90 141.00 143.10 145.20 147.30 149.40 151.50 153.60 155.70 157.70 159.80 161.90 163.90 166.00 168.10 170.10 172.20 174.20 176.30 178.30 180.30 182.40 184.40 186.40 188.40 190.50 192.50 194.50 196.50 198.50 5 94.10 96.29 98.47 100.70 102.80 105.00 107.10 109.30 111.50 113.60 115.80 117.90 120.00 122.20 124.30 126.40 128.60 130.70 132.80 134.90 137.00 139.10 141.20 143.30 145.40 147.50 149.60 151.70 153.80 155.90 157.90 160.00 162.10 164.10 166.20 168.30 170.30 172.40 174.40 176.50 178.50 180.50 182.60 184.60 186.60 188.60 190.70 192.70 194.70 196.70 198.70 6 94.32 96.51 98.69 100.90 103.00 105.20 107.40 109.50 111.70 113.80 116.00 118.10 120.20 122.40 124.50 126.60 128.80 130.90 133.00 135.10 137.20 139.30 141.40 143.50 145.60 147.70 149.80 151.90 154.00 156.10 158.10 160.20 162.30 164.30 166.40 168.50 170.50 172.60 174.60 176.70 178.70 180.70 182.80 184.80 186.80 188.80 190.90 192.90 194.90 196.90 198.90 7 94.54 96.73 98.91 101.10 103.30 105.40 107.60 109.70 111.90 114.00 116.20 118.30 120.50 122.60 124.70 126.90 129.00 131.10 133.20 135.30 137.40 139.60 141.70 143.80 145.90 147.90 150.00 152.10 154.20 156.30 158.40 160.40 162.50 164.60 166.60 168.70 170.70 172.80 174.80 176.90 178.90 180.90 183.00 185.00 187.00 189.00 191.10 193.10 195.10 197.10 199.10 8 94.76 96.95 99.13 101.30 103.50 105.60 107.80 109.90 112.10 114.30 116.40 118.50 120.70 122.80 124.90 127.10 129.20 131.30 133.40 135.50 137.70 139.80 141.90 144.00 146.10 148.20 150.20 152.30 154.40 156.50 158.60 160.60 162.70 164.80 166.80 168.90 170.90 173.00 175.00 177.10 179.10 181.10 183.20 185.20 187.20 189.20 191.30 193.30 195.30 197.30 199.30 9 94.98 97.17 99.35 101.50 103.70 105.80 108.00 110.20 112.30 114.50 116.60 118.80 120.90 123.00 125.20 127.30 129.40 131.50 133.60 135.80 137.90 140.00 142.10 144.20 146.30 148.40 150.50 152.50 154.60 156.70 158.80 160.80 162.90 165.00 167.00 169.10 171.10 173.20 175.20 177.30 179.30 181.30 183.40 185.40 187.40 189.40 191.50 193.50 195.50 197.50 199.50
13
Degrees Celsius versus Ohms value chart for 100 OHM Platinum RTD
C -17.78 -12.22 -6.67 -1.11 4.44 10.00 15.56 21.11 26.67 32.22 37.78 43.33 48.89 54.44 60.00 65.56 71.11 76.67 82.22 87.78 93.33 98.89 104.44 110.00 115.56 121.11 126.67 132.22 137.78 143.33 148.89 154.44 160.00 165.56 171.11 176.67 182.22 187.78 193.33 198.89 204.44 210.00 215.56 221.11 226.67 232.22 237.78 243.33 248.89 254.44 260.00 0.00 93.01 95.20 97.38 99.56 101.74 103.90 106.07 108.22 110.38 112.53 114.68 116.83 118.97 121.11 123.22 125.37 127.50 129.62 131.74 133.86 135.97 138.08 140.18 142.29 144.39 146.48 148.57 150.66 152.74 154.82 156.90 158.98 161.05 163.11 165.17 167.23 169.29 171.34 173.39 175.44 177.48 179.51 181.55 183.58 185.60 187.63 189.65 191.67 193.68 195.69 197.69 0.62 93.22 95.42 97.60 99.78 101.95 104.12 106.28 108.44 110.60 112.75 114.89 117.04 119.18 121.32 123.43 125.58 127.71 129.83 131.95 134.07 136.18 138.29 140.39 142.50 144.59 146.69 148.78 150.87 152.95 155.03 157.11 159.18 161.25 163.32 165.38 167.44 169.49 171.55 173.59 175.64 177.68 179.72 181.75 183.78 185.81 187.83 189.85 191.87 193.88 195.89 197.89 1.23 93.44 95.63 97.82 100.00 102.17 104.34 106.50 108.66 110.81 112.96 115.11 117.25 119.39 121.53 123.65 125.79 127.92 130.04 132.16 134.28 136.39 138.50 140.60 142.71 144.80 146.90 148.99 151.08 153.16 155.24 157.32 159.39 161.46 163.52 165.59 167.64 169.70 171.75 173.80 175.84 177.88 179.92 181.95 183.98 186.01 188.03 190.05 192.07 194.08 196.09 198.09 1.85 93.66 95.85 98.04 100.22 102.39 104.55 106.71 108.87 111.03 113.18 115.32 117.47 119.61 121.75 123.87 126.01 128.13 130.26 132.38 134.49 136.60 138.71 140.81 142.92 145.01 147.11 149.20 151.28 153.37 155.45 157.52 159.60 161.67 163.73 165.79 167.85 169.90 171.96 174.00 176.05 178.09 180.12 182.16 184.19 186.21 188.24 190.25 192.27 194.28 196.29 198.29 2.47 93.88 96.07 98.26 100.43 102.60 104.77 106.93 109.09 111.24 113.39 115.54 117.68 119.82 121.96 124.08 126.22 128.35 130.47 132.59 134.70 136.81 138.92 141.02 143.13 145.22 147.32 149.41 151.49 153.58 155.66 157.73 159.80 161.87 163.94 166.00 168.06 170.11 172.16 174.21 176.25 178.29 180.33 182.36 184.39 186.41 188.44 190.46 192.47 194.48 196.49 198.49 3.09 94.10 96.29 98.47 100.65 102.82 104.98 107.14 109.30 111.46 113.61 115.75 117.90 120.04 122.17 124.30 126.43 128.56 130.68 132.80 134.91 137.02 139.13 141.24 143.34 145.43 147.53 149.61 151.70 153.78 155.86 157.94 160.01 162.08 164.14 166.20 168.26 170.32 172.37 174.41 176.46 178.49 180.53 182.56 184.59 186.62 188.64 190.66 192.67 194.68 196.69 198.70 3.70 94.32 96.51 98.69 100.87 103.04 105.20 107.36 109.52 111.67 113.82 115.97 118.11 120.25 122.39 124.51 126.65 128.77 130.89 133.01 135.12 137.24 139.34 141.45 143.55 145.64 147.73 149.82 151.91 153.99 156.07 158.15 160.22 162.29 164.35 166.41 168.47 170.52 172.57 174.62 176.66 178.70 180.73 182.77 184.80 186.82 188.84 190.86 192.87 194.88 196.89 198.90 4.32 94.54 96.73 98.91 101.08 103.25 105.42 107.58 109.73 111.89 114.04 116.18 118.32 120.46 122.60 124.73 126.86 128.98 131.10 133.22 135.34 137.45 139.55 141.66 143.76 145.85 147.94 150.03 152.12 154.20 156.28 158.35 160.42 162.49 164.56 166.62 168.67 170.73 172.78 174.82 176.86 178.90 180.94 182.97 185.00 187.02 189.04 191.06 193.08 195.09 197.09 199.10 4.94 94.76 96.95 99.13 101.30 103.47 105.63 107.79 109.95 112.10 114.25 116.40 118.54 120.68 122.81 124.94 127.07 129.20 131.32 133.43 135.55 137.66 139.76 141.87 143.97 146.06 148.15 150.24 152.33 154.41 156.49 158.56 160.63 162.70 164.76 166.82 168.88 170.93 172.98 175.03 177.07 179.11 181.14 183.17 185.20 187.22 189.25 191.26 193.28 195.29 197.29 199.30 5.56 94.98 97.17 99.35 101.52 103.69 105.85 108.01 110.16 112.32 114.47 116.61 118.75 120.89 123.03 125.16 127.28 129.41 131.53 133.65 135.76 137.87 139.97 142.08 144.18 146.27 148.36 150.45 152.54 154.62 156.69 158.77 160.84 162.91 164.97 167.03 169.08 171.14 173.19 175.23 177.27 179.31 181.35 183.38 185.40 187.43 189.45 191.46 193.48 195.49 197.49 199.50
NOTE: This chart converted from Fahrenheit chart using formula C= ((F-32)/1.8)
14
Checking the RTD Transmitter 1. With control power off, connect a 100-ohm resistor to terminals #3 and #4 of the transmitter. 2. Turn control power on, the OUI reading should be 32F (0C) 5%. 3. If the reading is not within specification, the transmitter may be faulty.
TMS #3
BCM
Pin 25 Pin 1
123 4
100 OHM 5%
Temperature transmitter
15
Checking proper operation of the BCM and wiring
TMS #4
1. Ensure control power is off. At the affected RTD transmitter, disconnect the wires at transmitter terminal #1 and #2. Connect a 4-20mA source to these terminals (Observe correct polarity). Power up the control panel and then vary the simulator output. 2. At 12 mA (50%) the OUI should read 1/2 the RTD transmitter range; 250F (121.1C). The readout should change as the simulator output is varied. 3. If the reading on the OUI is incorrect or does not change, turn control power off and reconnect the transmitter, remove the wires for this transmitter from J1 and move the 4 to 20 mA simulator to the respective terminals at connector J1, (see electrical schematic for connection points). 4. Turn control power on and observe the OUI readout while varying the 4-20mA. If the reading is correct there is an open or short in the wire or terminals connecting the CMC to the RTD transmitter. If reading is not correct the BCM may be faulty.
BCM
Pin 25
4-20 mA SURCE OR 2 WIRE SIMULATOR
mA OUT 2 WIRE OFF
Pin 1
XXXXXX MODEL CL-XXX
BATTERY CHECK
00.0% - 100%
Input/Output (I/O) System

Temperature Monitoring System (TMS)
Description: 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004
555
LOOP ON
00.0%
100%
DIAL
16

A thermistor with external transmitter is used by the CMC for temperature monitoring. A thermistor resistance (ohmic value) varies with temperature. A transmitter for monitoring by the CMC analog input channel converts the resistance to a 4-20 mA signal.
Component specification: Probe: 10000 ohm resistance at 77 F (25C) The transmitter is mounted in the control panel enclosure. The transmitter is supplied 24 VDC and outputs 4-20mA over a fixed range of 30 to 250F (-34.4 to +121C). Transmitter:
Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem Troubleshooting Procedure High OUI readout High resistance connection TMS #4a Transmitter not calibrated TMS #3a Thermistor failure TMS #2a Transmitter failure TMS #3a Low OUI readout Transmitter failure TMS #3a Thermistor failure TMS #2a Transmitter not calibrated TMS #3a Erratic OUI readout Loose terminal connection TMS #4a Thermistor internal wire fault TMS #2a Transmitter failure TMS #3a Incorrect OUI readout Transmitter not calibrated TMS #3a Thermistor or transmitter failure TMS #2a, 3a Any TMS #1a, 2a, 3a, 4a Probable Cause
17
Checking for Power to the Temperature Transmitter TMS #1a 1. Disconnect the wires at terminals #1 and #2 on the transmitter and connect a voltmeter to these wires. 2. With control power on, there should be approximately 24 VDC present at the terminals. 3. If approximately 24 VDC is not present, see the section titled Control Power System.
18
Checking for a Faulty Thermistor 1. Turn control power off. 2. Check ohms versus temperature. Use an Ohmmeter and table below to determine if the thermistor is faulty. Vary the temperature to the thermistor and check the ohms around the normal operating range.

TMS #2a
Temperature, oF 50 75 77 90 150 212 228 239

1.92o 1.88o 1.88 o 1.84 o 1.69 o 1.41 o 1.33 o 1.30 o
Resistance, ohms 20250 10520 10000 7572 1962 637.0 491.4 413.9
5.24% 4.73% 4.73% 4.41% 3.75% 2.35% 2.11% 2.00%
Temperature vs. Resistance Chart for 10000 ohm at 77 oF Thermistor
19
Checking the Thermistor Transmitter
TMS #3a
4. With control power off, connect a 10000-ohm resistor to terminals #3 and #4 of the transmitter. 5. Turn control power on, the OUI reading should be 77F (25C) 5%. 6. If the reading is not within specification, the transmitter may be faulty.
20

TMS #4a
Checking proper operation of the BCM and wiring
1. Ensure control power is off. At the affected thermistor transmitter, disconnect the wires at transmitter terminal #1 and #2. Connect a 4-20mA source to these terminals (Observe correct polarity). Power up the control panel and then vary the simulator output. 2. At 12 mA (50%) the OUI should read 1/2 the thermistor transmitter range; 110F (43.3C). The readout should change as the simulator output is varied. 3. If the reading on the OUI is incorrect or does not change, turn control power off and reconnect the transmitter, remove the wires for this transmitter from J1 and move the 4 to 20 mA simulator to the respective terminals at connector J1, (see electrical schematic for connection points). 4. Turn control power on and observe the OUI readout while varying the 4-20mA. If the reading is correct there is an open or short in the wire or terminals connecting the CMC to the thermistor transmitter. If reading is not correct the BCM may be faulty.
BCM
Pin 25
mA OUT 2 WIRE OFF
Pin 1
XXXXXX MODEL CL-XXX
BATTERY CHECK
00.0% - 100%
555
LOOP ON
00.0%
100%
DIAL

Pressure Monitoring System (PMS)
Description: A Pressure Transducer (PT) is used to convert pressure (psi) to a 4-20 mA signal for monitoring by the CMC. Component specification: 0 to 14.7 PSIG (101.35 kpa) range 0-100 PSIG (689.5 kPa) range 0-200 PSIG (1379 kPa) range Power = 24 VDC The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem Zero OUI readout Probable Cause Open circuit/cable disconnected Loss of power to transmitter Malfunctioning transmitter Loose wire/terminal/connector Any Troubleshooting Procedure PMS #1, 2 PMS #1 PMS #3, 4 PMS #1,2 PMS #1, 2, 3, 4
21
Troubleshooting:
Erratic OUI readout Incorrect OUI readout
22
Checking for Power to the Pressure Transmitter
PMS #1
1. Ensure control power is off. Disconnect the wires at the suspect PT and connect a voltmeter to these wires. 2. With control power on, there should be approximately 24 VDC present at the terminals. 3. If approximately 24 VDC is not present, see the section titled Control Power System.
BCM
Pin 25 Pin 1
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
VDC
mA
VAC
INGERSOLL RAND
mA COM V
23
Checking proper operation of the BCM and wiring PMS #2 1. Ensure control power is off. Disconnect the wires at the suspect PT and connect a 4-20 mA source to the lifted wires (Observe correct polarity). 2. Restore control power and then vary the simulator output. 3. At 12 mA (50%) the OUI should read 1/2 the PT range. The readout should change as the simulator output is varied. 4. If the reading on the OUI is incorrect or does not change, turn control power off and reconnect the transmitter, remove the wires for this transmitter from J1 and move the 420 mA simulator to the respective terminals at connector J1, (see electrical schematic for connection points). 5. Turn control power on and observe the OUI readout while varying the 4-20 mA. If the reading is correct there is an open or short in the wire or terminals connecting the CMC to the PT. If the reading is not correct the BCM may be faulty.
BCM
Pin 25
mA OUT 2 WIRE OFF
Pin 1
XXXXXX MODEL CL-XXX
BATTERY CHECK
00.0% - 100%
555
LOOP ON
00.0%
100%
DIAL
24
Quick check of the PT 1. Connect an ohmmeter to the disconnected wires coming from the PT. 2. If there is no continuity either the wiring or the PT is faulty.
PMS #3
M
XXXXX XXXXX XXXXX
XXXXX
XXXXX
XXXXX
VDC
mA
VAC
mA COM V
INGERSOLL RAND
Functional PT test
PMS #4
1. Remove control power. 2. Remove the PT and connect a regulated air supply to the pressure connection. Power up the CMC and vary the regulated air supply. The OUI should read the pressure being applied.

Digital Input System (DIS)
Description: The digital input devices associated with the CMC are on/off devices that turn on or off the associated CMC digital input. Typical digital device name and type: 1. 2. 3. 4. 5. 6. Starter Feedback Main motor overload Fan motor overload Remote start/stop Condensate level switch (option) Auxillary inputs
25
Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem False alarm or trip Probable Cause Faulty device Faulty wiring Troubleshooting Procedure DIS #1 DIS #1
26
Checking proper operation of the digital devices DIS #1 1. Verify approximately 24 VDC is present as described in the section titled Troubleshooting the Power System. 2. If approximately 24 VDC is present, install a multimeter with VDC selected between J4 or J5 pin1 and the input pin (the input pin can be determined from the electrical schematic, or wire number). 3. Ensure the digital device is not in the trip condition, the meter should read 0 VDC. 4. Actuate the switch, the meter should read approximately 24 VDC.
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Control Power System (CPS)

Description: The control power system provides 24 VDC to the CMC system for processing logic, displaying data, and monitoring instrumentation. The 24 VDC power supply feeds the Base Control Module (BCM) at connector J10. Over current protection and power distribution are performed as shown below:
J2 +24 VDC pins 11 thru 14 Return pins 7 thru 10 Power Supply

F1
J1
AC2 pin 3 BCM shown cover removed
AC1 pin 1 Fuse 5A/250VAC, normal blo. J12-Digital Output Power 120 VAC (Pin 1)
To OUI J2 pin 2
To OUI J2 pin 1
OUI Power
To Ground Bar
J10-Power Input (24 VDC)

F103 F102 F101 F100
J9-Current Transformer (0-5 amp)
CPU Power All BCM Fuses are 5x20mm, GMA 1.5 amp, Fast Blow Digital Input Power J4 & J5 - Digital Input Power 24 VDC (pin 1)
BCM
Analog Input/Output Power
LEGEND: Trace Wire
J3- Analog Output Power 24 VDC (pins 2 & 8)
J1- Analog Input Power 24 VDC (pin 26)
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Power Supply:
Input power: 85-132 VAC, or 180-264 VAC (auto-selecting input), 2.5A RMS max, 47-63 Hz. Output power: 24 VDC, 4.3 A maximum at 50 C. The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause:
Troubleshooting:
Typical Problem All analog inputs are zero or negative on System Page
Probable Cause No AC power No DC power No analog input power Cable disconnected No CPU power BCM problems No AC power No DC power No OUI power No AC power No DC power No digital input power No AC power No DC power No digital output power
Troubleshooting Procedure CPS #1 CPS #2 CPS #5
OUI displays: OUI Port: RS232 Address: 0x0141 OUI Display Table CRC: D672 BCM Not Responding
OUI is black
Event Log indicates all digital alarms and trips active
CPS #8 CMCS #3 CPS #1 CPS #2 CPS #7 CPS #1 CPS #2 CPS #3 CPS #1 CPS #2 CPS #4
All digital outputs not working
No AC power CPS #1 1. Ensure control power is off. 2. Install a multimeter set for VAC between pins 1 and 3 at connector J1 on the power supply. 3. Restore control power, the meter should read 120 VAC or 220 VAC depending upon the rated supply power. The rated supply power can be verified from the electrical schematic.
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No DC power CPS #2 1. Ensure control power is off. 2. Install a multimeter set for VDC between pins 11-14 and 7-10 at connector J2 on the power supply. 3. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F1 on the power supply, if fuse is good, the power supply may be faulty. 4. Ensure control power is off. 5. Install a multimeter set for VDC between pins 1 and 2 at connector J10 on the BCM. 6. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check the wiring between the power supply and the BCM. No digital input power CPS #3 1. Ensure control power is off. 2. Install a multimeter set for VDC between pin 1 at connector J4 on the BCM and the ground bar. 3. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F103 on the BCM, if F103 is good, check for DC power. No digital output power CPS #4 1. Ensure control power is off. 2. Install a multimeter set for VAC between pin 1 at connector J12 on the BCM and the ground bar. 3. Restore control power, the meter should read 120 VAC. No analog input power CPS #5 1. Ensure control power is off. 2. Install a multimeter set for VDC between pin 26 at connector J1 on the BCM and the ground bar. 3. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F102 on the BCM, if F102 is good, check for DC power. No OUI power CPS #7 1. Ensure control power is off. 2. Install a multimeter set for VDC between pins 1 and 2 at connector J2 on the OUI. 3. Restore control power, the meter should read approximately 24 VCD. If approximately 24VDC is present, check F2 on the OUI. If F2 is good, go to next step. 4. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F101 on the BCM, if F101 is good, check for DC power.
No CPU power CPS #8 1. Ensure control power is off. 2. Verify approximately 24 VDC is present at J10. 3. Check F100, if F100 is blown the BCM must be replaced, not the fuse. 4. If F100 is not blown, and the BCM is not functioning, the BCM must be replaced.
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Controller Problems
Description: The CMC System is generally comprised of a Base Control Module (BCM), Operator User Interface (OUI), and Power Supply (PS). There are few user serviceable components within the system; however, a brief understanding of the system will help in overall troubleshooting. All components require 24 VDC and rely on hardware and software to perform correctly, if the problem cannot be isolated to a power problem it is most likely a hardware or software problem, which will require Ingersoll-Rand support to correct. Component Specification: 24 VDC power required Software required for BCM and OUI
Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem BCM fault suspected OUI is dim OUI is black OUI displays: OUI Port: RS232 Address: 0x0141 OUI Display Table CRC: D672 BCM Not Responding OUI displays: OUI Port: RS232 Address: 0x0141 OUI Display Table CRC: D672 BCM Display Table CRC: 6C24 OUI / BCM Waiting for Tables (*.ABS) OUI displays Status XXH Where XX is a specific number Probable Cause No power Wrong contrast selected Backlight failing No power Cable disconnected Troubleshooting Procedure CMCS #4 CMCS #1 CMCS #1 CMCS #2 CMCS #3
Wrong program in either the BCM or the OUI
Program appropriate module with correct file.
Many
MODBUS communications problem No power Many
Refer to Status Codes under System Information Section. CMCS #5 Refer to the UCM Section.

BCM Problems
BCM is not controlling CMCS #4 1. Check the CPU power as described in the section titled Control Power System.
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OUI Problems
OUI is dim CMCS #1 1. Depress the contrast key to step to the desired brightness. 2. Replace the OUI backlight as described in the section titled Backlight Replacement Procedure. If the backlight does not fix the problem the OUI may be faulty. OUI is black CMCS #2 1. Check for OUI power as described in the section titled Control Power System. If approximately 24 VDC is present, check F2. If F2 is O.K. the OUI may be faulty. OUI displays OUI Port: RS232 Address: 0x0141 OUI Display Table CRC: D672 BCM Not Responding 1. Check the cabling between OUI J1 and BCM J6. 2. Check the BCM CPU power. 3. The BCM may be faulty. CMCS #3
UCM Problems
All UCM LEDs are not lit 1. Check for approximately 24 VDC at pins 1 and 2 at J3 on the UCM. 2. If power is present at J3 the UCM may be faulty. CMCS #5
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Communication
Customers may want to communicate to the CMC control systems for remote compressor control and monitoring. This communication capability provides for flexibility in the customer's compressed air operation through remote start and stop, data gathering for preventative maintenance, and incorporation into plant-wide control system. The major avenue for communicating with the CMC is via MODBUS protocol over an RS422/485 hardware link. This requires hardware for the control panel, and a communications device with the appropriate driver software to perform the desired panel functions. The RS422/485 interface can communicate with any serial device that has an RS422 or RS485 port. The customer or his representative must write system software to suit his individual needs for remote control and monitoring. Since the customer writes this interface, the system can be as flexible as the customer desires. Remote communications will be disabled through the UCM until the Remote Communications are enabled. Remote communications are enabled through the OUI. When this setting is set to YES, remote communications through the UCM will be possible.
Human Machine Interface (HMI) Systems

Air System Controller (ASC) and Air System Manager (ASM) are software packages available for compressors with CMC panels. ASC and ASM are graphical integration software specifically developed for air compressor systems. Both provide energy management through load sharing and reduction of air bypass by using a minimum amount of energy to meet the system demand. The primary goal of both systems is to maintain stable system pressure, to integrate, monitor and control the compressed air system. ASM is the integration of compressor control software in an off-the-shelf Supervisor Control and Data Acquisition (SCADA) package that is available from various manufacturers. The ASM provides more custom features than does ASC. Both ASC and ASM provide a window into the compressor room by making the raw data from compressors and other equipment available to plant operators and managers in formats that are easy to understand. Implementing the CMC in any HMI system may require additional hardware and/or software upgrade.
Direct CMC Communications with RS422/485

For the descriptions that follow, a serial device can be a Personal Computer (PC), Programmable Logic Controller (PLC), Distributed Control System (DCS) or any other device that can transmit, receive and interpret an RS422/485 formatted signal over a hardware link. In the descriptions that follow, the PC and PLC serial devices are not specific to manufacturers or operating systems. There are many ways of interfacing to CMC control systems through an RS422/485 port. Most of the following methodologies are currently available; but please be aware, other possible configurations can exist. All RS422/485 interfaces require custom interface software and custom application software. The interface software allows a specific serial device and operating system to transmit, receive and interpret data from a CMC control system. The application software 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004

tells the CMC control system what to do; for example, start compressor when ready, stop compressor after midnight and retrieve the current data and save to a disk file. Currently there are hundreds of different serial devices using different operating systems and languages in the industrial equipment world. Therefore, the practicality of having an interface for many systems is limited. Custom interfaces must be written as required by the hardware and operating system used. The capabilities of the hardware and the imagination of the developer only limit the application software. For example, one developer may have two compressors. In this application the developer wants a screen to display the compressor interstage pressure and temperatures for both machines with various other compressor data. A second developer has five compressors. He also wants to display the same data, but this time for all five machines. The only way this is done is through changing the application software (custom modification). The developer may write functions to read and display data, log that data to some magnetic media for storage, change compressor set points, sequence the compressors for efficient operation and network additional devices, such as pumps, dryers, etc., into the system. All of these functions require specially written application software for the intended use.
33
The CMC-MODBUS Interface

Introduction
The CMC can communicate with other devices over a variety of communications standards. Supported standards, or protocols, include RS-232, IRBUS (Ingersoll-Rand Proprietary), and Modicons MODBUS. The built-in ports on the CMCs optional Universal Communication Adapters access communications. The CMC-MODBUS Interface defines the message structure that a CMC uses to exist on a MODBUS network. This interface will allow the MODBUS network to gather information and control the compressor. NOTE Unless specified otherwise, numerical values (such as addresses, codes, or data) are expressed as decimal values in the text of this section. They are expressed as hexadecimal values in the message fields of the examples.
34

In order to communicate over other types of networks, a network adapter must be used. The information presented in the following sections does not include MODBUS protocol details like framing messages and calculating checksums. This detailed information can be obtained from Schneider Automations MODBUS PROTOCOL Manual, Chapters 1 through 6. This can be obtained through the Internet at www.modicon.com.
Query
Master
Device Address Function Code Data Address Data CRC
Slave
Device Address Function Code Byte Count Data CRC
Serial Modes
MODBUS Controllers can be setup to communicate on MODBUS networks using either of two transmission modes: ASCII or RTU. The CMC supports only the RTU mode. The user must specify the serial port communication parameters (baud rate, parity mode, etc.) during configuration of each CMC. The mode and serial parameters must be the same for all devices on a MODBUS network.
Response
Figure 3: MODBUS Messages
MODBUS Messages
A MODBUS network uses a master-slave relationship (Figure 3). The CMC always acts as a slave device. The slave cannot initiate a message, and returns a message (response) only to queries (reads) that are addressed to them individually. For example, a force coil command (write to module) that is broadcast to all MODBUS devices would not get a response. Responses are not returned to broadcast writes from the master.
Device Address
This address is the physical address of the Universal Communication Module (UCM) for the compressor. This address must be unique in the MODBUS network. The valid range for this address is 01-FF (hexadecimal). NOTE: 00 (hexadecimal) is reserved for broadcast. Configuration of the slave address is available through the Ingersoll-Rand Service Tool and will be provided by a certified Ingersoll-Rand Service Representative.
Function Code
The listing below shows the function codes that are supported by the CMC. Additional detail about each function is provided in sections that follow.
Function Code (decimal) 1 2 3 4 5 6 15 16 Function Code (hex) 01 02 03 04 05 06 0F 10 Function Name Read Coil Status Read Input Status Read Holding Registers Read Input Registers Force Single Coil Preset Single Register Force Multiple Coils Preset Multiple Registers

Data Addresses
Addresses that contain the data type and a four-digit number are referred to as absolute (e.g., address 30232, where 3 is the data type for a input register and 0232 or 232 is the address). Software products at the operator or user level use absolute addresses most frequently.
35
The addresses that do not contain the type and are referenced to zero are referred to as relative (e.g., absolute address 30232 would be relative address 231, remove the data type 3, holding register, and subtract 1 for referencing to zero). All data addresses in MODBUS messages (typically, behind the scenes at the programming communication level) are referenced to zero; that is, the first occurrence of a data item is addressed as item number zero.
MODBUS Range Absolute Addresses 00001-09999 10001-19999 30001-39999 40001-49999 MODBUS Range Relative Addresses 0000-9998 0000-9998 0000-9998 0000-9998 CMC Range Absolute Addresses 00001-09000 10001-19000 30001-39000 40001-49000 CMC Range Relative Addresses 0000-8999 0000-8999 0000-8999 0000-8999
Reference 0x 1x 3x 4x
Data Type Coils Discrete Inputs Input Registers Holding Registers
Absolute address for Coil 00127 decimal is relatively addressed as coil 007E hex (126 decimal) Input register with absolute address of 30001 is relatively addressed as register 0000 in the data address field of the message. The function code field that specifies reading or writing data already specifies an input register operation; therefore, the 3x reference is implicit. Holding register with an absolute address of 40108 is relatively addressed as register 006B hex (107 decimal)
Single Module Addresses The addresses provided in this document are for compressors with a single Base Control Module. Multiple Module Addresses For those systems that require multiple Base Control Modules, the addresses for the first module will be as provided within this document. The addresses for the second module will be provided as an engineering submittal.
Data
For both queries and responses, the data is in sixteen bit (two bytes, one word) chunks. For each two byte word, the left most byte is the most significant. For each byte, the left most bit is the most significant. This portion of the message changes with each function code. See the detail that follows for each function for the specifics of this message component.
Byte Count
The number of bytes contained in the data portion of the message. This is used on both queries (reads) and responses.
36
Cyclical Redundancy Check (CRC)
This portion of the message is used to prevent incorrect data from being used in the Master or Slave because of communication errors.
Function Details
Function 01 - Read Coil Status
This function reads the state of one or more coils (MODBUS 0x references) in the slave (CMC Base Control Module). For the CMC, these coils represent the Discrete (Digital) Outputs, compressor operating state (see the Operator User Interface Status Bar for definition), any compressor Trip condition and any compressor Alarm condition. If the function returns a 1, the discrete output is on. If the function returns a 0, the discrete output is off. Broadcast is not supported. Refer to the table on the next page for MODBUS Absolute Addresses for each coil supported by the CMC-MODBUS Interface.
Absolute Relative Absolute Relative Address Address Coil Name - Read Only* Address Address Coil Name - Read Only* (decimal) (hex) (decimal) (hex) 00195 00-C2 Remote Indication Trip 00305 01-30 Stage 2 Hi Temperature Trip 00196 00-C3 PORO Restart Pending 00306 01-31 Stage 2 Hi Temperature Alarm 00197 00-C4 Remote Indication Alarm 00361 01-68 Main Motor Overload Alarm 00198 00-C5 Stopped in Auto Restart 00362 01-69 Main Motor Overload Trip 00199 00-C6 Load Solenoid Valve 00363 01-6A Fan Motor Overload Alarm 00200 00-C7 Condensate Solenoid Valve 00364 01-6B Fan Motor Overload Trip 00201 00-C8 CR2 00383 01-7E Auxiliary Input 1 Alarm 00202 00-C9 CR1 00384 01-7F Auxiliary Input 1 Trip 00203 00-CA Compressor State - Waiting 00385 01-80 Auxiliary Input 2 Alarm 00204 00-CB Compressor State - Coasting 00386 01-81 Auxiliary Input 2 Trip 00205 00-CC Compressor State - Starting 00388 01-83 Condensate Level Trip 00206 00-CD Compressor State - Not Ready 00447 01-BE Calibration OK 00207 00-CE Compressor State - Ready 00448 01-BF Lag Mode 00208 00-CF Compressor State - Unloaded 00449 01-C0 Lag Mode Enabled on OUI 00209 00-D0 Compressor State - Loaded 00450 01-C1 Remote Start / Stop Enabled on OUI 00210 00-D1 Compressor State Started Disabled 00451 01-C2 Remote Communications Enabled on OUI 00211 00-D2 Compressor State Auto Restart Ready 00452 01-C3 Condensate Level Switch Enabled 00218 00-D9 Any Compressor Trip 00453 01-C4 PORO Enabled 00219 00-DA Any Compressor Alarm 00454 01-C5 Scheduled Start / Stop Enabled 00297 01-28 Stage 1 Hi Temperature Trip 00455 01-C6 Remote Trouble Indication 00298 01-29 Stage 1 Hi Temperature Alarm * IMPORTANT: These coils are defined as read only. If you decide to write to these coils, unexpected results could occur.
Example: Reading a Single Coil After reviewing the Electrical Schematic for your compressor, you determine that the digital output for the load solenoid valve is located on J12-P7,8 (Channel 13). From the table above, the Absolute Address is decimal 00199 (Relative Address is hexadecimal 00C6) for the output in question. Therefore, to read the state of the load solenoid valve output the following command is issued (the following data are presented in hexadecimal format):
Device Address 01 Function Code 01 Address Hi Lo 00 C6 Number of Coils Hi Lo 00 01 CRC Lo 1D Hi F7
37
The response from this command is:

Device Address 01 Function Code 01 Byte Count 01 CRC Data 01 Lo 90 Hi 48
The data (01) means that the discrete output is on, or the load solenoid valve is energized. Example: Reading Multiple Coils To read all sixteen digital (discrete) outputs, the following command is sent:
Device Address 01 Function Code 01 Address Hi Lo 00 BA Number of Coils Hi Lo 00 10 CRC Lo 1C Hi 23
where relative address 00-BA is for digital (discrete) output for Channel 1. The response from this command is:
Device Address 01 Function Code 01 Byte Count 02 CRC Data 04-10 Lo BA Hi F0
To determine the state of each output, review the Electrical Schematic for your compressor. For this example, you determine that the digital output for the load solenoid valve is located on J12-P7,8 (Channel 13) and the digital output for the condensate solenoid valve contact is J12-P5,6 (Channel 14). For the eight channels (16-9) the hexadecimal data byte 10 (0010 0000 binary) means that Channels 16, 15, 12, 11, 10 and 9 are off and Channel 13 (load solenoid valve) and 14 (condensate solenoid valve) is energized. The following table graphically depicts this example:
Response Byte 2 Address 16 0 C9 15 0 C8 14 1 C7 13 1 C6 12 0 C5 11 0 C4 10 0 C3 9 0 C2
A bit response of 1 means that the output is on and a response of 0 means that the output is off.
Function 02 - Read Input Status

This function reads the state of one or more discrete inputs (MODBUS 1x references) in the slave (CMC Base Control Module). For the CMC, these inputs represent the Discrete (Digital) Inputs. If the function returns a 1, the input is on. If the function returns a 0, the input is off. Broadcast is not supported. Refer to the table on the next page for MODBUS Absolute Addresses for each discrete input supported by the CMC-MODBUS Interface.
38

Absolute Address Relative Address Input Name - Read Only* (decimal) (hex) 10171 00-AA 1M 10172 00-AB 2M 10173 00-AC Main Motor Overload 10174 00-AD Fan Motor Overload 10175 00-AE E-Stop 10179 00-B2 Remote Start 10180 00-B3 Remote Stop 10181 00-B4 Remote Lag 10182 00-B5 Remote Load Enable 10183 00-B6 Remote Load 10184 00-B7 Auxiliary Input 1 10185 00-B8 Auxiliary Input 2 10186 00-B9 Condensate Level Switch NOTE: (J4-P2) is interpreted as Connector J4, Pin 2 on the Base Control Module. * IMPORTANT: These Digital Inputs are defined as read only. If you decide to write to these Inputs, unexpected results could occur.
Example: Read Single Discrete Input After reviewing the Electrical Schematic for your compressor, you determine that the digital input for fan motor overload is located on J4-P5 (Channel 4). From the table above, the Absolute Address is decimal 10174 (Relative Address is hexadecimal 00AD) for the input in question. Therefore, to read the state of the fan motor overload the following command is issued (the following data are presented in hexadecimal format):
Device Address 01 Function Code 02 Address Hi Lo 00 AD Number of Digital Inputs Hi Lo 00 01 CRC Lo 28 Hi 2B

Device Address 01 Function Code 02 Byte Count 01 CRC Data 01 Lo 60 Hi 48
The data (01) means that the input is on, or the fan motor overloads have tripped. Example: Read Multiple Discrete Inputs The method for reading multiple Discrete Inputs is the same as reading multiple coils. See the example for Reading Multiple Coils.

Function 03 - Read Holding Registers
Reads the binary content of holding registers (MODBUS 4x references) in the slave (CMC Base Control Module). For the CMC, these holding registers contain the Analog Output values and Analog Alarm and Trip Setpoint values for all CMC inputs and outputs. Broadcast is not supported. The CMC is primarily a 32-bit floating-point microprocessor controller. And, since MODBUS is designed to be a 16-bit system, the CMC supports two methods for determining the value for each holding register (This also applies to Input Registers.) NOTE Since MODBUS is a 16-bit system, the programmer must get two 16-bit numbers and combine them into one 32-bit floating-point number.
39
The first method uses two 16-bit integers to represent the integer and fraction part of the value. The second method uses one 32-bit IEEE floating point number. (NOTE: For those who would like to only get the 16-bit integer value, this will work well for most inputs; however, the CMC has some inputs, that might be less than one. Since the CMC has programmable analog and discrete inputs and outputs, the programmer must use the electrical schematic supplied with the contract to determine which function name and units of measure are associated with each input and output. Refer to the table below for MODBUS Absolute Addresses for each Holding Register supported by the CMC-MODBUS Interface.
Signed IEEE 32-Bit Float Absolute Relative Address Address (Decimal) (hex) 43141 0C-44 43143 0C-46 43157 0C-54 43159 0C-56 43285 0C-D4 43293 0C-DC 43297 0C-E0 43299 0C-E2 43301 0C-E4 43303 0C-E6 43305 0C-E8 43307 0C-EA
Holding Register Name - Read/Write Stage 1 Hi Temperature Trip Setpoint Stage 1 Hi Temperature Alarm Setpoint Stage 2 Hi Temperature Trip Setpoint Stage 2 Hi Temperature Alarm Setpoint Start Timer Auto Start Pressure Power On Hours Running Hours Loaded Hours Number of Starts Wait Timer Coast Timer
40

Signed IEEE 32-Bit Float Absolute Relative Address Address (Decimal) (hex) 44201 10-68 44203 10-6A 44205 10-6C 44207 10-6E 44209 10-70 44211 10-72 44213 10-74 44215 10-76 44217 10-78 44219 10-7A 44221 10-7C 44223 10-7E 44225 10-80 44227 10-82 44229 10-84 44243 10-92 44245 10-94 44247 10-96 44249 10-98 44251 10-9A 44253 10-9C
Holding Register Name - Read/Write Rated Pressure Online Pressure Offline Pressure Online Pressure Setpoint Offline Pressure Setpoint Lag Offset Pressure Lead / Lag Cycle Hours Starter Type Oil Filter Differential Pressure Auto Stop Timer (Minutes) Condensate Interval Time Condensate Release Time Load Delay PORO Delay PORO Time Remaining Scheduled Start Day Scheduled Start Hour Scheduled Start Minute Scheduled Stop Day Scheduled Stop Hour Scheduled Stop Minute
Example: See example for Function 04.
Function 04 - Read Input Registers

Reads the binary content of input registers (MODBUS 3x references) in the slave (CMC Base Control Module). For the CMC, these input registers refer to the Analog Input values. Broadcast is not supported. The CMC is primarily a 32-bit floating-point microprocessor controller. And, since MODBUS is designed to be a 16-bit system, the CMC supports two methods for determining the value for each holding register. (This also applies to Input Registers.) The first method uses two 16-bit integers to represent the integer and fraction part of the value. The second method uses one 32-bit IEEE floating point number. NOTE Since MODBUS is a 16-bit system, the programmer must get two 16-bit numbers and combine them into one 32-bit floating-point number.
For those who would like to only get the 16-bit integer value, this will work well for most inputs; however, the CMC has some inputs, that may be less than one.

Signed IEEE 32-Bit Float Absolute Relative Input Register Name - Read Only* Address Address (Decimal) (hex) Inlet Vacuum Pressure 33007 0B-BE Stage 2 Inlet Pressure 33009 0B-C0 Stage 2 Discharge Pressure 33011 0B-C2 Package Discharge Pressure 33013 0B-C4 Oil Filter Inlet Pressure 33015 0B-C6 Bearing Oil Pressure 33017 0B-C8 Stage 1 Discharge Temperature 33023 0B-CE Stage 2 Inlet Temperature 33025 0B-D0 Stage 2 Discharge Temperature 33027 0B-D2 Bearing Oil Temperature 33029 0B-D4 Package Discharge Temperature 33031 0B-D6 . * IMPORTANT: These Input Registers are defined as read only. If you decide to write to these Input Registers, unexpected results could occur.
41
Example: Read Single Channel 16-Bit Integer and Fraction After reviewing the Electrical Schematic for your compressor, you determine that the analog input for System Pressure is located on J1-P1 (Channel 3). From the table above, the Absolute Address is decimal 30007 (Relative Address is hexadecimal 0006) for the input in question. Therefore, to read the 16 Bit Integer and 16 Bit Fraction for System Pressure the following command is issued (the following data are presented in hexadecimal format):
Device Address 01 Function Code 04 Address Hi Lo 00 06 Number of Registers Hi Lo 00 02 CRC Lo 91 Hi CA

Data Device Address 01 Function Code 04 Byte Count 04 Reg-1 Hi 00 Lo 64 Hi 13 Reg-2 Lo 4E Lo 37 CRC Hi 5F
Register 1 is the Integer portion of the System Pressure or (0064h, 100 decimal). Register 2 is the Fraction portion of the System Pressure or (134Eh, 4942 decimal). Each fraction has a range between 0 and 9999. So the System Pressure, expressed as a floating point number is 100.4942 psi. Example: Read Single Channel IEEE 32-Bit Floating Point Number To continue with the example, when you decide to get the System Pressure as an IEEE 32 Bit floating point number you must issue the following command:
Device Address 01 Function Code 04 Address Hi Lo 0B BE Number of Registers Hi Lo 00 02 CRC Lo 13 Hi CB

Data Device Address 01 Function Code 04 Byte Count 04 Reg-1 Hi 42 Lo DC Hi D4 Reg-2 Lo C6 Lo F1 CRC Hi 54
42
So the Inlet Vacuum Pressure, expressed as a floating point number is 110.4155731201 psi. IEEE floating-point numbers are represented in 32 bits as shown below.
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 exponent sign mantissa 9 8 7
6
Convert hexadecimal registers 1 and 2 (Reg-1, Reg-2) into decimal values ...
Register 1 1 2 2 Byte Hi Lo Hi Lo Symbol R1HB R1LB R2HB R2LB Hex 42 DC D4 C6 Decimal 66 220 212 198
Determine the sign (positive = 0 or negative = 1) ... Sign = (R1HB And 128) / 128, where And is defined as a bit-wise And Sign = (66 And 128) / 128 = 0 Determine the exponent ... Exponent = ((R1HB And 127) 2) + INT(R1LB / 128), where INT is defined as INTEGER Exponent = ((66 And 127) 2) + INT(220/128) = 133 Determine the mantissa... Mantissa = ((((R1LB And 127) 256) + R2HB) 256) + R2LB Mantissa = ((((220 And 127) 256) + 212) 256) + 198 = 6083782 Putting the 32 bit IEEE value together... Value = (-1sign) (2(exponent - 127)) ((Mantissa 2-23) + 1) Value = (-10) (2(133- 127)) ((6083782 2-23) + 1) = 110.4155731201 NOTE When Sign = Exponent = Mantissa = 0, Value = 0. This is a special case for the above equation. Example: Read Multiple Channels The procedure for reading multiple channels is the same as reading a single channel with the exception of requesting more data. NOTE: You must read a contiguous group of registers (channels) for a single command.
Function 05 - Force Single Coil

Forces a single coil (MODBUS 0x references) to either ON or OFF. When broadcast, the function forces the same coil reference in all attached slaves. Refer to the table below for MODBUS Absolute Addresses for each coil supported by the CMC-MODBUS Interface. 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004

NOTE The Force Single Coil command will override the CMCs current state. The forced state will remain valid until the CMC next solves the coil. The coil will remain forced if it is not programmed in the CMC logic.
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CAUTION
For all of the following Remote Coils, the compressors REMOTE COMMUNICATIONS ENABLED selection must be in the ENABLED position for these commands to execute. When DISABLED, the CMC ignores (there is no exception response) these coils being forced ON or OFF.
Absolute Address (decimal) 00221 00222 00223 00224 00225 00226
Relative Address (hex) 00-DC 00-DD 00-DE 00-DF 00-E0 00-E1
Coil Name - Write Only Remote Horn Silence (Acknowledge) Remote Reset Remote Load Remote Unload Remote Start Remote Stop
Example: Forcing a Coil For all MODBUS devices, a value of FF 00 hex requests the coil to be ON. A value of 00 00 requests it to be OFF. All other values are illegal and will not affect the coil. NOTE: For the CMC, forcing the above listed coils OFF is not meaningful because the default state of each of the above coils is OFF. When using these commands, they should be sent once (momentary) and the CMC will execute the commands. To remotely reset the compressor, the following command is issued:
Device Address 01 Function Code 05 Address Hi Lo 00 DD Forced Data Hi FF Lo 00 Lo 1C CRC Hi 00
The response from this command is identical to the command sent:

Device Address 01 Function Code 05 Address Hi Lo 00 DD Number of Registers Hi Lo FF 00 CRC Lo 1C Hi 00
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Function 06 - Preset Single Register
Presets a value into a single holding register (MODBUS 4x reference). When broadcast, the function presets the same register reference in all attached slaves. Refer to the table for the Holding Register list for the MODBUS Absolute Addresses supported by the CMCMODBUS Interface. NOTE The Preset Single Register command will override the CMCs current state. The preset value will remain valid in the register until the CMC logic next solves the register contents. The register's value will remain if it is not programmed in the controller's logic.
CAUTION
This function can only set a single 16-bit holding register. Since the CMC operates with 32-bit values, you must use Function 16 (10 Hex) - Preset Multiple Registers for setting the 32-bit IEEE register values. Also, you may not set the 16-bit fraction without its 16-bit integer. Therefore, you must use the Preset Multiple Registers function to send this 32-bit pair. See the examples that follow for Function 16.
CAUTION
The position of the REMOTE COMMUNICATIONS ENABLED selection is NOT considered when forcing coils or writing registers to the CMC. Reads and Writes are always enabled. Repeatedly writing a value to a register or forcing a coil without regard to the position of the switch can effectively disable a local write. Please use caution when writing registers or forcing coils. The REMOTE COMMUNICATIONS ENABLED selection is typically located on the Settings tab of the Compressors Control Panel operator user interface.
Example: Presetting a Single Register (16-bit) Integer To change the integer value for the Online Pressure Setpoint (absolute address 44207, relative address 10-6E) to 100 (00-64 hex) psi, send the following command...
Device Address 01 Function Code 06 Address Hi Lo 10 6E Register Value Hi Lo 00 64 CRC Lo ED Hi 3C
The response from this command is identical to the command sent:

Device Address 01 Function Code 06 Address Hi Lo 10 6E Register Value Hi Lo 00 64 CRC Lo ED Hi 3C
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Function 15 (0F Hex) - Force Multiple Coils

Forces each coil (MODBUS 0x reference) in a series of contiguous coils to either ON or OFF. When broadcast, the function forces the same coil references in all attached slaves (CMC Base Control Modules). Refer to the table for the Coil list for the MODBUS Absolute Addresses supported by the CMC-MODBUS Interface.
NOTE The Force Multiple Coils command will override the CMCs current state. The forced state will remain valid until the CMC next solves the coil. The coil will remain forced if it is not programmed in the controller's logic.
CAUTION
Example: Forcing Multiple Coils To force a reset (absolute address 00222, relative address DD) and start (absolute address 00225, relative address E0) of the compressor the following command is sent...
Device Address 01 Function Code 0F Address Hi Lo 00 DD Number of Coils Hi Lo 00 04 Number of Data Bytes 01 Coil Data Lo 09 CRC Lo 12 Hi 83
The number of contiguous coils is four (00225, 00224, 00223 and 00222). The number of data bytes is one because we can set up to eight coils in a single byte. The coil data is nine because we want to set the first bit and fourth bit in the byte (0000-1001, the bytes are numbered right to left). All bits not used are padded with zero. The response from this command is similar to the command sent except that the number of data bytes and the coil data themselves are not echoed:
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Device Address 01 Function Code 0F Address Hi Lo 00 DD Number of Coils Hi Lo 00 04 CRC Lo Hi C4 32
Function 16 (10 Hex) - Preset Multiple Registers

Presets values into a sequence of contiguous holding registers (MODBUS 4x references). When broadcast, the function presets the same register references in all attached slaves (CMC Base Control Modules). Refer to the table for the Input Register list for the MODBUS Absolute Addresses supported by the CMC-MODBUS Interface. NOTE The Preset Multiple Registers command will override the CMCs current state. The forced state will remain valid until the CMC next solves the register. The register will remain forced if it is not programmed in the controller's logic.
CAUTION
Example: Presetting Holding Registers for 32-bit Values The difficulty in setting 32-bit values is determining the four data bytes for the number you want to send. The process required is... 1. 2. Determine the sign (positive = 0 or negative = 1). This is the first bit. Divide the decimal value by 2 until the result is less than 2, but greater than 1. Count the number of iterations required. Add 127 to the number of iterations. This result is the exponent. Convert this result to binary. These are the next eight bits. From the result obtained from step 2, subtract 1. Then, multiply this result by 2. If the result is less than 1, then the value of the first mantissa bit is 0. Otherwise, the mantissa bit is 1. If the result is greater than or equal to 1, then subtract 1 from the result and proceed with step 3 until the result is 0 or you have gone through this process 23 times. Combine all 32 bits from the steps above and convert this value to hexadecimal. These 32 bits are the 4 hexadecimal data bytes needed for the command.
3.
4.

As an example, we will start with the decimal value of 105.4. 1. Since this is a positive number, the first bit is 0. 2. Determine the exponent bits by ... It took us six iterations to get the result to a number that is less than two and greater than or equal to one. Now, we must add 127 for an exponent of 133. Converting this to binary, the next eight bits are represented as 10000101. 3. Determine the mantissa bits by From the table at right, 0100101100110011001100 represent the next 23 bits. 4. Combining the bits in sign, exponent and then mantissa order ... 0100-0010-1101-0010-1100-1100-1100-1100 This converts to 42-D2-CC-CC in hexadecimal. To change the holding registers for user pressure setpoint (for 32 bit IEEE floating point numbers the absolute address is 43269, relative address 0C-C4) to 105.4, issue the following command...
Iteration 1 2 3 4 5 6 Iteration 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Decimal 105.40000 52.70000 26.35000 13.17500 6.58750 3.29375 Decimal 1.646875 1.29375 0.5875 1.175 0.35 0.7 1.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 Result 52.700000 26.350000 13.175000 6.587500 3.293750 1.646875 Result 1.29375 0.5875 1.175 0.35 0.7 1.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 Bit 1 0 1 0 0 1 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0
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/ / / / / /
2 2 2 2 2 2
= = = = = =
Operatio n -1*2= -1*2= *2= -1*2= *2= *2= -1*2= *2= -1*2= -1*2= *2= *2= -1*2= -1*2= *2= *2= -1*2= -1*2= *2= *2= -1*2= -1*2= *2=
Device Address 01
Function Code 10
Address Hi Lo 0C C4
Number of Registers Hi Lo 00 02
Number of Data Bytes 04
Data Bytes for Register #1 Hi Lo 42 D2
Data Bytes for Register #2 Hi Lo CC CC
CRC Lo 4A Hi 18
The response from this command is similar to the command sent except that the number of data bytes and the data bytes themselves are not echoed:
Device Address 01 Function Code 10 Address Hi Lo 0C C4 Number of Registers Hi Lo 00 02 CRC Lo 03 Hi 65
NOTE Sending 32 bit values are typically not necessary. Sending the data as a 16 bit integer only or a 16 bit integer and 16 bit fraction will satisfy most requirements. Some systems have 32 bit capability built directly into their products. We have provided this feature for those systems.
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CAUTION
Example: Presetting a 16-bit Integer and 16-bit Fraction Holding Register Change the integer and fraction value for the user pressure setpoint (absolute address 40269, relative address 01-0C) to 110.5 psi. The integer portion of the number 110 (00-6E hex) is placed at address 40269 and the fraction 0.5 is converted to 5000 (13-88 hex) and is placed at address 40270 (or the second data byte). To change the register, issue the following command...
Device Address 01 Function Code 10 Address Hi Lo 01 0C Number of Registers Hi Lo 00 02 Number of Data Bytes 04 Data Bytes for Register #1 Hi Lo 00 6E Data Bytes for Register #2 Hi Lo 13 88 CRC Lo 92 Hi E1
The response from this command is similar to the command sent except that the number of data bytes and the data bytes themselves are not echoed:
Device Address 01 Function Code 10 Address Hi Lo 01 0C Number of Registers Hi Lo 00 02 CRC Lo 80 Hi 37
Exception Responses
Except for broadcast messages, when a master device sends a query to a slave device it expects a normal response, in all other cases a time out or exception response is returned. The four possible responses to a the master's query are: If the slave device receives the query without a communication error, and can handle the query normally, it returns a normal response. If the slave does not receive the query due to a communication error, no response is returned. The master program will eventually process a time-out condition for the query. If the slave receives the query, but detects a communication error (parity, or CRC), no response is returned. The master program will eventually process a time-out condition for the query. If the slave receives the query without a communication error, but cannot handle it (for example, if the request is to read a nonexistent coil or register), the slave will return an exception response informing the master of the nature of the error.
The exception response message has two fields that differentiate it from a normal response: 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004

Function Code Field
For a normal response, the UCM echoes the function code of the original query in the function code field of the response. All function codes have their most significant bits set to zero; therefore, the values are always below 80 hexadecimal. When an exception response occurs, the UCM sets the most significant bit of the function code to 1. This makes the function code value in an exception response exactly 80 hexadecimal higher than the value would be for a normal response.
7 1 Most Significant Bit 6 5 4 0 0 0 3 0 Least Significant Bit 2 1 0 0 0 0
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With the function code's most significant bit set, the application program can recognize an exception response and can examine the data field for the exception code.
Data Field
For a normal response, the UCM will return information in the data field (depending upon the query message sent). For an exception response, the UCM returns an exception code in the data field. This defines the UCMs condition that caused the exception.
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Exception Codes Supported by the CMC Microcontroller

Code 01 Name Illegal Function Meaning The function code received in the query is not an allowable action for the slave. This exception code happens when: (1) the function code is other than 1, 2, 3, 4, 5, 6, 15 or 16 (2) a message has the incorrect number of bytes for the function specified The data address received in the query is not an allowable address for the slave. This exception code happens when: (1) the address is not programmed into the Base Control Module (BCM) (2) the address is outside of the ranges (a) 00001-00512 for coils (b) 10001-10512 for discrete inputs (c) 30001-31024 for integer and fractional analog inputs (d) 33001-34024 for floating point analog inputs (e) 40001-41024 for integer and fractional input registers (f) 43001-44024 for floating point analog input registers A value contained in the query data field is not an allowable value for the slave. This exception code happens when: (1) the number of coils, discrete inputs, registers or analog inputs is equal to zero (2) request for more than the maximum number of parameters (3) the force single coil command, Function 05, is issued and the value is other than FF00 or 0000 (4) the force multiple coil command, Function 15, is issued and the number of bytes does not equal the number of bits to set (5) the preset single register command, Function 6, or preset multiple registers commands, Function 16, is issued and the starting address is not even, or the number of registers specified does not correspond to the number of bytes in the message, or the integer part of the number is outside the range 32768 to +32767, or the fractional part of the number is outside of the range 0-9999, or the value is not a valid 32 bit IEEE floating point number An unrecoverable error occurred while the slave was attempting to perform the requested action. This exception code happens when: (1) no response from the Base Control Module (BCM) since 800 milliseconds from the time the message was sent BCM not wired properly, BCM hardware problem or BCM Module ID not equal to one (2) when there is an unexpected response from the BCM this is the default exception response
02
Illegal Data Address
03
Illegal Data Value
04
Slave Device Failure
Maximum Query / Response Parameters

The listing below shows the maximum amount of data that the CMC Microcontroller can return in a single slave response from a valid MODBUS command.
Function Dec Hex 01 01 02 02 03 03 04 04 05 05 06 06 15 0F 16 10 Description Read Coil Status Read Input Status Read Holding Registers Read Input Registers Force Single Coil Preset Single Register Force Multiple Coils Preset Multiple Registers Maximum Parameters 512 coils 512 inputs 64 registers 64 registers 1 coil 1 register 512 coils 64 registers
CMC Data
The CMC Microcontroller supports several data types. They are coil, integer, fraction and floating point. Coil - 1 bit, 1 means True or Active, 0 means False or Not Active. Integer - 16 bit signed integer, 32768 to +32767. 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004

Fraction - 16 bit unsigned integer, 0 9999, represents the decimal (fractional) part of the number (1 represents 0.0001, 10 represents 0.0010, 100 represents 0.0100 and 1000 represents 0.1000). Floating Point - 32 bit IEEE number (requires reading two registers to get full number).
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For example if the Inlet Vacuum Pressure input is located on Channel 3 (address 33007) and the value of the pressure is 100.5 then: Address 30007 contains 100 Address 30008 contains 5000 Address 33007 contains the high 16 bits of the IEEE value for 100.5 Address 33008 contains the low 16 bits of IEEE value for 100.5 Additionally, the type of data in a location determines the commands that can be used to access the data. For the previous example of System Pressure addresses 00007, 03007, 10007, 13007, 40007 and 43023 return errors because coil, input status and holding register commands cannot read input register data.
Scaling and Units of Measure

The MODBUS data are scaled in English engineering units. All pressures are in psi and temperatures are in degrees F. For example, when the CMC Operator User Interface displays the system pressure as 7.73 kg/cm2, the value for system pressure obtained through MODBUS communications is 110 psi.
Communication Parameters
Configuration of the communication speed (baud rate), parity, number of data bits and number of stop bits is available through the Ingersoll-Rand Service Tool and will be provided by a certified Ingersoll-Rand Service Representative.
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The CMC-DF1 Interface

Introduction
Customers may want to communicate to the CMC control systems for remote compressor control and monitoring through their Allen-Bradley data highway plus (DH+) network. Adding Allen-Bradley DF1 protocol to the UCM module allows our customers to incorporate our compressors into their plant-wide Allen-Bradley PLC control system. This communication capability also provides for flexibility in the customer's compressed air operation through remote start, stop, and data gathering for preventative maintenance. The customer or his representative must write system software to suit his individual needs for remote control and monitoring. Since the customer writes this interface, the system can be as flexible as the customer desires. One avenue for communicating with the CMC is via DF1 protocol over a full duplex RS-422 link. This requires an Allen-Bradley interface module 1770-KF2 to link our intelligent RS422A asynchronous device, Universal Communication Module (UCM), to the Allen-Bradley DH+ network. The CMC Microcontroller can communicate with other devices over a variety of communication standards. Supported standards, or protocols, include RS-232, IRBUS (Ingersoll-Rand Proprietary), Modicons MODBUS, and Allen-Bradley DF1. The built-in ports of the CMCs Universal Communication Module access communications. This UCMDF1 Interface defines the message structure that a CMC Microcontroller uses to exist on a DH+ network. This interface will allow the DH+ network to gather information and control the compressor. The information presented in these sections that follow do not include the Allen-Bradley DF1 protocol details. Detailed information can be obtained from Allen-Bradley Publication 1770-6.5.117 - October 1996 - DF1 Protocol and Command Set Reference Manual and Data Highway or Data Highway Plus Asynchronous (RS-232-C or RS-422-A) Interface Module (Cat. No. 1770-KF2) Users Manual. A DH+ link implements peer-to-peer communication with a token-passing scheme to rotate mastership among the nodes connected to that link. In order to communicate over AllenBradley DH+ network, an Allen-Bradley 1770-KF2 interface module must be used. The 1770-KF2 always acts as one node on the DH+ network, which translates DH+ messages to DF1 format, and passes these messages on to the UCM on the RS-422A asynchronous end, or vice versa. The following is a picture of 1770-KF2:

Full-Duplex Protocol
The UCM-DF1 interface only supports the point-to-point full-duplex DF1 protocol, which is like a two-lane bridge; traffic can travel in both directions at one time. Full-duplex protocol also provides higher performance applications to get the highest possible throughput.
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DF1 Full-Duplex Protocol Message Frames

The following table shows the general format of a DF1 full-duplex message frame. The control symbols DLE STX bytes are sender symbols indicating the start of a message frame. The control symbols DLE ETX BCC (CRC) bytes are sender symbols that terminates a message frame. The bytes comprised in the command data field vary from command to command.
DLE STX DST SRC CMD STS TNS Command Data DLE ETX BCC(CRC)
NOTE The standard definitions of the control characters used by DF1 full-duplex protocol are listed below:
Abbreviation STX ETX ENQ ACK DLE NAK
Hexadecimal Value 02 03 05 06 10 0F
DF1 Device Address

Configuration of the DF1 device address is available through the Ingersoll-Rand UCMWizard Tool and will be configured by a certified Ingersoll-Rand Service Representative. CAUTION
The UCM must be configured to have the same node address as 1770-KF2 interface module. Otherwise, the DF1 messages will not be relayed to the IRBUS port of the UCM.
Destination (DST) Byte

This byte indicates the destination node address for the message. For a command message, it will be the address of the 1770-KF2 module. The UCM must have the same address as the 1770-KF2, which can be configured using the Ingersoll-Rand UCM-wizard software.
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Source (SRC) Byte
This byte indicates the source node address of the message. If the command is initiated from an Allen-Bradley PLC, the SRC byte will be the address of the processor module.
Command (CMD) and Function (FNC) Bytes

The CMD byte defines the command type. The FNC byte defines the specific function under that command type. These bytes together define the activity being performed by the command message at the destination node. The message format depends on the CMD and FNC values. CMD Byte
Bit: 7 0 6 0:Command msg 1:Reply msg 5 0: normal priority(for DH+) 1: high priority(only applies to DH link) 4 0 3 2 1 0 Command code
From the figure above, the CMD byte of a reply message for DH+ network is always 40h ORed with the CMD byte of its original command message.
Status (STS) Byte - Status Error Code

Bit: 7 6 5 4 Remote Error Nibble 3 2 1 0 Local Error Nibble
Bits 7, 6, 5, and 4 are used to report remote errors - errors that occur when the command executor at the destination node tries to execute the command message. Bits 3, 2, 1, and 0 are used to report local errors - errors found by the local source node and code 09h through 0Fh are not used. The UCM-DF1 driver uses mainly the higher nibble to report errors occur in CMC. A special error code with non-zero local error nibble, 3Fh, is used to report errors caused by illegal CMC data table address or count. The maximum number of data table entries allowed to be read or set for CMC is 16 currently. If a read command requests more than 16 data items from CMC, an exception response of 3Fh will be returned. Following is a list of status error code supported by the UCM-DF1 driver:
Transaction (TNS) Bytes

The two TNS bytes contain a unique 16-bit transaction identifier. Generate this number by maintaining a 16-bit counter. Increment the counter each time your command initiator creates a new message, and store the counter value in the two TNS bytes of the new message. You must use only one TNS counter in a multi-tasking environment. If the command initiator is an Allen-Bradley PLC, the PLC will maintain the counter internally. The reply message should have the same TNS value as the original command message. The UCM-DF1 driver copies the original TNS field of the command message into the TNS field of the corresponding reply message.
BCC (Block Check Character) and CRC (Cyclic Redundancy Check)

At the end of each DF1 command message, there is a one-byte BCC field, or a two-byte CRC field for error checking. These bytes allow you to verify the accuracy of each message frame transmission. SW-1 of 1770-KF2 module allows you to select BCC or CRC error checking for the command messages sent to CMC. The Ingersoll-Rand UCM-wizard 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004

software allows you to configure BCC or CRC error checking for the UCM-DF1 driver, which needs to be the same error checking method as 1770-KF2. BCC (One Byte) The BCC field contains the 2s compliment of the 8-bit sum of all data bytes between DLE STX and DLE ETX BCC control characters. BCC provides a medium level of data security. It cannot detect either the transposition of bytes during transmission nor the insertion or deletion of the value zero within a message frame. Another way to quickly determine a BCC value, add up the hex values of all data bytes between DLE STX and DLE ETX BCC in the message frame. If the total is greater than 100h, drop the most significant digit, and then subtract the result from 100h. This gives you the BCC. CRC (Two Bytes) This provides a higher level of data security than BCC but is more difficult to implement. All the data bytes between DLE STX and DLE ETX CRC plus the ETX byte are used to calculate the CRC value. The following explains how to calculate the CRC value: Before starting the calculation, a 16-bit register used to store the CRC value is cleared to be zero. As a byte is fetched from the data buffer, it is XORed (least-significant bit to the right) with the right eight bits of the CRC register. The result is placed in the right eight bits of the CRC register. Inserting 0s on the left then shifts the 16-bit CRC Register right eight times. Each time a 1 is shifted out on the right, the CRC register is XORed with a 16-bit constant A0-01h. As each additional byte is fetched, it is included in the value in the register the same way. After the ETX byte transmitted is also included in the calculation, the CRC calculation is complete. The 16-bit CRC value is transmitted low byte first then high byte.
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Comparing the calculated BCC/CRC bytes with the received BCC/CRC bytes always validates the DF1 messages received by UCM. CAUTION
To transmit the data value of 10 hex, you must use the data symbol DLE DLE (double-stuffing DLEs). However, only one of these DLE bytes is included in the BCC/CRC calculation. However, if your BCC check sum is 10 hex, send it as DLE and not DLE DLE. The rest of this section explains the meaning of the data bytes between DLE STX and DLE ETX BCC/CRC control characters. Usually, a command message stripping off the control characters has the following format, 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004
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DST SRC CMD STS

TNS command specific data packet
a reply message to a read command has the format below,

SRC DST CMD STS TNS command specific data packet
a reply message to a write command has the following format,

SRC DST CMD STS TNS
The DST and SRC bytes of a reply message are formed by interchanging the DST and SRC bytes of the corresponding command message. The combination of SRC, CMD, and TNS bytes uniquely identifies every message packet. If all fields are the same, the message is considered to be a duplicate. The UCM-DF1 driver does not detect duplicate messages.
Scaling and Units of Measure

The MODBUS data are scaled in English engineering units. All pressures are in psi and temperatures are in degrees F. For example, when the CMC Operator User Interface displays the system pressure as 7.73 kg/cm2, the value for system pressure obtained through MODBUS communications is 110 psi.
Data Addressing
The CMC is primarily a 32-bit floating-point microprocessor controller. We support two methods for determining the analog data value. These methods are two 16-bit integers representing the integer and fraction part of the number and one 32-bit IEEE floating point number. (NOTE: If you use the 16-bit system, you must get two 16-bit numbers and combine them into one 32-bit floating point number.) The UCM-DF1 interface can prepare data as either two 16-bit integers or one 32-bit floating point number with respect to the received DF1 command. The Allen-Bradley PLC floating point format is a subset of IEEE STD 754-1985. Accessing data from the CMC via DF1 interface emulates accessing data from a PLC5 or SLC5/04. In SLC 5/04, each data file can hold up to 256 data elements (element number: 0255) and the file number has to be in the same range (0-255). The UCM-DF1 addressing scheme uses this file/element structure and complies with the SLC5/04s limits on file number and element number. Please see next section for details. A DF1 command initiator is a device on the DH+ network that initiates the query or set commands to the CMC. It can be an Allen-Bradley PLC or other device that can send/receive a PLC5 Typed Read (Write) or SLC Typed Logical Read (Write) command/response.
CMC as PLC5
As to treating CMC as a PLC5, the command initiator can issue a PLC5 Typed Read (Write) command to the CMC. Please see the section on Supported Functions for detailed message format. For a PLC5 Typed Write command, the data can be sent as either two 16-bit integers or one 32-bit floating point. If a PLC5 or SLC5/04 issues the command, the setpoint data type is determined by the local data file type used to store it. 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004

The PLC5 Typed Read commands for requesting data in integer or float format is exactly the same messages. The UCM-DF1 driver cannot tell the requested data type from the command bytes received. Therefore, the returned data type has to be pre-configured in UCM via the Ingersoll-Rand UCM-wizard tool. Default is the integer type. If a PLC5 or SLC5/04 issues the command, the local data file used to store the gathered data should be the same type. Otherwise, you get erroneous data or an error status code due to data type mismatch.
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CMC as SLC5/04
As to treating a CMC as a SLC5/04, the command initiator can issue a SLC Typed Logical Read (Write) command to the CMC. Please see the section on Supported Functions for detailed message format. If the command initiator is another SLC5/04, you can do either integer or float data type. However, if the command initiator is a PLC5, only integer type is supported for the time being.
Data File Addressing for PLC5/SLC504

When RSLogix software is used to program message instructions in PLC for sending read/write commands to the CMC, the target data table address is in the form of either Fxx:yyy or Nxx:yyy, where xx is the file number (10-14) and yyy (0-255) is the corresponding CMC data table address. The target file type (F for float, N for integer) should be consistent with the local file type. NOTE File numbers 10-14 are reserved for address only!
The UCM-DF1 interface designates file number 10 for discrete usage (READ ONLY). Each element represents 16 Boolean data bit-packed together in two bytes. File type can be either N (integer) or B (bit) type. The following table shows the address in file 10 for discrete values.
PLC File Address B10:10 B10:11 B10:12 B10:13 CMC Data Table Address (decimal) 160-175 176-191 192-207 208-223 15 175 191 207 223 14 174 190 206 222 13 173 189 205 221 12 172 188 204 220 11 171 187 203 219 16 Discretes Packed as Binary Bits in Two Bytes 10 9 8 7 6 5 170 169 168 167 166 165 186 185 184 183 182 181 202 201 200 199 198 197 218 217 216 215 214 213 4 164 180 196 212 3 163 179 195 211 2 162 178 194 210 1 161 177 193 209 0 160 176 192 208
Bit 10-15 of integer element 10 in data file 10 represents digital input channels 1-6 (CMC data table address 170-175). Bit 0-9 of integer element 11 represent digital input channels 7-16 (CMC data table address 176-185). Bit 10-15 of integer element 11 represents digital output channels 1-6 (CMC data table address 186-191). Bit 0-9 of integer element 12 represent digital output channels 7-16 (CMC data table address 192-201). Bit 10-15 of integer element 11 represents digital output channels 1-6 (CMC data table address 186191). Bit 10-15 of integer element 12 and bit 0-10 of integer element 13 represent various compressor states (CMC data table address 202-218). Currently, CMC data table has 512 entries. In order to satisfy the (0-255) limit of elements per data file for SLC5/04, the CMC data table is divided into two segments; each has 256 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004
58

entries. File number 11 is designated to the first 256 entries. File number 12 is for the second 256 entries. If the CMC data table gets expanded later, the subsequent file number will be used. According to the above, N11:170 refers to the 170-th item in the CMC data table, which is the digital input channel 1. Similarly, N12:170 will be the 426-th = (170+256) item in the CMC data table. If an invalid file or element number is used, you will get a 3Fh-status error code. See the status error code section for details. The number of bytes per element is 2 for integer type and 4 for float type. The assigned message length in elements for local data file should be a multiple of 2 for integer type. If it is an odd number, only the 2-byte integer (whole) part will be transmitted for the last data item. Since the CMC has programmable analog and discrete inputs and outputs, the programmer must use the electrical schematic supplied with the machine to determine which function name and units of measure are associated with each input and output.
CMC Data Addressing

Refer to the table below for data addresses supported by the UCM-DF1 Interface.
Data Data Data Data

Address (decimal) 3 4 5 6 7 8 11 12 13 14 15 70 71 78 79 142 146 148 149 150 151 152 153 170 171 172 173 174 178 179 180 181 182 183 184 185 194 195 196 197 198 199 201 202 203 204 205 206 207 208 209 Address (hex) 03 04 05 06 07 08 0B 0C 0D 0E 0F 46 47 4E 4F 8E 92 94 95 96 97 98 99 AA AB AC AD AE B2 B3 B4 B5 B6 B7 B8 B9 C2 C3 C4 C5 C6 C7 C9 CA CB CC CD CE CF D0 D1 Description Inlet Vacuum Pressure Stage 2 Inlet Pressure Stage 2 Discharge Pressure Package Discharge Pressure Oil Filter Inlet Pressure Bearing Oil Pressure Stage 1 Discharge Temperature Stage 2 Inlet Temperature Stage 2 Discharge Temperature Bearing Oil Temperature Package Discharge Temperature Stage 1 Discharge Temperature Hi Trip Setpoint Stage 1 Discharge Temperature Hi Alarm Setpoint Stage 2 Discharge Temperature Hi Trip Setpoint Stage 2 Discharge Temperature Hi Alarm Setpoint Start Timer Auto Start Pressure Power on hours Running Hours Loaded Hours Number of starts Wait Timer Coastdown Timer 1M 2M Main Motor Overload Fan Motor Overload E-Stop Remote Start Remote Stop Remote Lag Remote Load Enable Remote Load Auxiliary Input 1 Auxiliary Input 2 Condensate Level Remote Trip Indication PORO Restart Pending Remote Alarm Indication Stopped in Auto Restart Load Solenoid Valve Condensate Solenoid Valve CR1 Compressor State - Waiting Compressor State - Coasting Compressor State Starting Compressor State - Not Ready Compressor State - Ready Compressor State - Unloaded Compressor State - Loaded Compressor State Start Disabled Address (decimal) 210 217 218 220 221 222 223 224 225 296 297 304 305 360 361 362 363 382 383 384 385 387 446 447 448 449 450 451 452 453 454 600 601 602 603 604 605 606 607 608 609 610 611 612 613 614 621 622 623 624 625 626 Address (hex) D2 D9 DA DC DD DE DF E0 E1 128 129 130 131 168 169 16A 16B 17E 17F 180 181 183 1BE 1BF 1C0 1C1 1C2 1C3 1C4 1C5 1C6 258 259 25A 25B 25C 25D 25E 25F 260 261 262 263 264 265 266 26D 26E 26F 270 271 272 Description Compressor State - Auto Restart Ready Any Compressor Trip Any Compressor Alarm Remote Acknowledge Remote Reset Remote Load Remote Unload Remote Start Remote Stop Hi Stage 1 Temperature Trip Hi Stage 1 Temperature Alarm Hi Stage 2 Temperature Trip Hi Stage 2 Temperature Alarm Main Motor Overload Alarm Main Motor Overload Trip Fan Motor Overload Alarm Fan Motor Overload Trip Auxiliary Input 1 Alarm Auxiliary Input 1 Trip Auxiliary Input 2 Alarm Auxiliary Input 2 Trip Condensate Level Trip Calibration OK Lag Mode Lag Mode Enabled on OUI Remote Start/Stop Enabled on OUI Remote Communication Enabled on OUI Condensate Level Switch Enabled PORO Enabled Scheduled Start/Stop Enabled Remote Trouble Indication Rated Pressure Online Pressure Offline Pressure Online Pressure Setpoint Offline Pressure Setpoint Lag Offset Pressure Lead / Lag Cycle Hours Starter Type Oil Filter Differential Pressure Auto Stop Timer Minutes Condensate Interval Time Condensate Release Time Load Delay PORO Delay PORO Time Remaining Scheduled Start Day Scheduled Start Hour Scheduled Start Minute Scheduled Stop Day Scheduled Stop Hour Scheduled Stop Minute
59
60
Supported Functions
The listing below shows the DF1 commands supported by the CMC Microcontroller.
Command Code (hex) 0F 0F 0F 0F Function Code (hex) 68 67 A2 AA Function Name PLC5 Typed Read PLC5 Typed Write SLC Typed Logical Read SLC Typed Logical Write
Command 0F/Function 68 - PLC5 Typed Read

The CMC is treated as a PLC5 when this command is issued. This command reads a block of data from CMC starting at a specified data table address. As to the format of floating point number, Allen-Bradley DF1 protocol always put low byte first then high byte, low word first then high word, which is different from the UCMMODBUS protocol. The byte format for a floating point value, 105.4, is differentiated between the two interfaces as below (Byte 1 to 4 is in the order of transmission):
Protocol UCM-MODBUS UCM-DF1 Floating Point Byte Representation Byte 1 Byte 2 Byte 3 Byte 4 42 D2 CC CD CD CC D2 42
Example: Reading an Analog Input After reviewing the Electrical Schematic for your compressor, you determine that the analog input for system pressure is located on J1-P1 (Channel 3). From the CMC data table above, the address is 03h. The UCM should be configured to represent data type as desired. Following is a table illustrating how the PLC5 system address is mapped to the CMC data table address.
CMC Data Address 3 254 255 256 259 PLC5 Target Data Table Address N11:3 N11:254 N11:255 N12:0 N12:3 PLC5 System Address Element File Number 0B 03 0B FE 0B FF FF 0C 00 0C 03
07 07 07 07 07
00 00 00 00 00
00
As 16-Bit Integer and Fraction To get the reading of system pressure as 16-bit integer and 16-bit fraction, the following command is issued (data are presented in hexadecimal format):
DLE 10 STX 02 DST 0D SRC 11 CMD 0F STS 00 TNS 21 BD FNC 68 Packet Offset 00 00 Total Trans 02 00 PLC5 System Address 07 00 0B 03 02 Size 00 DLE 10 ETX 03 BCC 74

DLE STX DST SRC CMD STS TNS A B DLE ETX BCC

10 02 11 0D 4F 00 21 BD 99 09 05 42 64 00 5C 09 10 03 03
61
In the response above, the first two bytes (low byte first then high byte) in field B is the integer portion of the system pressure (00-64h, 100 decimal). The second two bytes in field B are the fraction portion of the system pressure (09-5Ch, 2396 decimal). Each fraction has a range between 0 and 9999. So the system pressure, expressed as a floating-point number, is 100.2396 PSIG. The following table contains a list of data types and the ID value of each supported by Allen-Bradley DF1 protocol:
Data Type ID 1 2 3 4 5 6 7 8 9 15 16 Data Type bit bit string byte (or character) string integer Allen-Bradley timer Allen-Bradley counter Allen-Bradley general control structure IEEE floating point array of similar elements address data binary-coded decimal (BCD)
The first byte, 99h, in field A of the above response message is a flag byte, which has the format below:
Bit: 7 1 Data Type ID 6 5 0 0 4 1 3 1 Data Type Size 2 1 0 0 0 1
If the data type ID is greater than 7, set bit 7 of this flag byte to 1 and insert the number of bytes to follow that contains the data type ID value in bits 4, 5, and 6. These additional ID bytes follow directly after the flag byte. In the above response message, the additional one byte is 09h, which means array of similar elements. If the data type defined uses more than 7 bytes for each data element, enter 1 in bit 3 of the flag byte and enter the number of bytes to follow that contains the number of bytes used for each data element. These additional size bytes follow the flag byte and any ID bytes. The individual bytes in field A and B of the above response message is explained in the following table:
Field Byte (hex) 99 09 05 42 64 00 5C 09 Definition flag byte data type ID byte: array of similar elements number of bytes to follow descriptor byte 4: type ID for integer 2: two bytes per element 4 data bytes
62
As IEEE 32-Bit Floating Point Number If the UCM is configured to read data as floating point, the following command is sent:
DLE 10 STX 02 DST 0D SRC 11 CMD 0F STS 00 TNS 21 BD FNC 68 Packet Offset 00 00 Total Trans 01 00 PLC5 System Address 07 00 0B 03 01 Size 00 DLE 10 ETX 03 BCC

DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 21 BD 99 09 A 06 B 94 08 C6 D4 DC 42 DLE 10 ETX 03 BCC
The individual bytes in field A and B of the above response message is explained in the table below:
Field Byte (hex) 99 09 06 94 08 C6 D4 DC 42 means flag byte data type ID byte: array of similar elements number of bytes to follow descriptor byte 9: one byte to follow 4: four bytes per element type ID for floating point 4 data bytes
After the proper byte swapping, the system pressure (42-DC-D4-C6), expressed as a floating point number is 110.4155731201 PSIG. IEEE floating-point numbers are represented in 32 bits as shown below.
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 exponent sign mantissa 9 8 7
6
Convert hexadecimal words 1 and 2 (W1, W2) into decimal values ...
Word Lo 1 Lo 1 Hi 2 Hi 2 Byte Lo Hi Lo Hi Symbol W1LB W1HB W2LB W2HB Hex C6 D4 DC 42 Decimal 198 212 220 66
Determine the sign (positive = 0 or negative = 1) ... Sign = (W2HB And 128) / 128, where And is defined as a bit-wise And Sign = (66 And 128) / 128 = 0 Determine the exponent ... Exponent = ((W2HB And 127) * 2) + INT (W2LB / 128), where INT is defined as INTEGER Exponent = ((66 And 127) * 2) + INT (220/128) = 133 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004

Determine the mantissa... Mantissa = ((((W2LB And 127) * 256) + W1HB) * 256) + W1LB Mantissa = ((((220 And 127) * 256) + 212) * 256) + 198 = 6083782 Putting the 32 bit IEEE value together... Value = (-1sign) * (2(exponent - 127)) * ((Mantissa * 2-23) + 1) Value = (-10) * (2(133- 127)) * ((6083782 * 2-23) + 1) = 110.4155731201 NOTE When Sign = Exponent = Mantissa = 0, Value = 0. This is a special case for the above equation.
63
Example: Read Multiple Analog Channels The procedure for reading multiple channels is the same as reading a single channel with the exception of requesting more data. The message length in elements should be set as desired but no more than 16 data at a time, because IRBUS can handle at most 16 data in one query for the time being. NOTE A contiguous group of data (channels) must be read for a single command.
Example: Reading a Discrete Value Reading discrete values from file number 11 or higher is the same as reading analog data. To read a digital output (Channel 3, 188h) as a two-byte integer, the following command is sent:
DLE 10 STX 02 DST 0D SRC 11 CMD 0F STS 00 TNS A1 C2 FNC 68 Packet Offset 00 00 Total Trans 01 00 PLC5 System Address 07 00 0B BC Size 01 00 DLE 10 ETX 03 BCC 38
The response to this command is:

DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS A1 C2 A 99 09 03 42 01 B 00 DLE 10 ETX 03 BCC 48
Example: Reading Multiple Discrete Values To read digital output channels 1-6 as integers, the following command is sent:
DLE 10 STX 02 DST 0D SRC 11 CMD 0F STS 00 TNS 41 17 FNC 68 Packet Offset 00 00 Total Trans 0C 00 PLC5 System Address 07 00 0B BA Size 0C 00 DLE 10 ETX 03 BCC 2F
The response to this command is:

DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 41 17 A 99 09 19 42 00 00 00 00 00 00 B 00 00 01 00 00 00
DLE
ETX
BCC
64
00 00 00 00 00 00 00

00 00 00 00 00 10 03 3D
Example: Reading Bit-Packed Discrete Data Reading discrete values from file number 10 is to read the 16 bit-packed discrete values in a two-byte integer format. When the following command is sent,
DLE 10 STX 02 DST 0D SRC 11 CMD 0F STS 00 TNS 61 C4 FNC 68 Packet Offset 00 00 Total Trans 01 00 PLC5 System Address 07 00 0A 0B 01 Size 00 DLE 10 ETX 03 BCC 28
the response from this command is:

DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 61 C4 A 99 09 03 42 28 B 10 10 DLE 10 ETX 03 BCC 4F
NOTE The data value 10h in field B is transmitted as 10h 10h to be distinguished from the control character DLE. Please see the DF1 Full-Duplex Protocol Message Frames section for more details.
In the above example, the local data file type can be either bit or integer types. Local data element B10:11 covers CMC data table address 176-191. You can determine the remote load contact (Channel 13, J5-P6) by bit 6 in the returned integer. The table below graphically depicts the individual bit value for the returned two-byte integer.
Response (hex) Byte 1 28 Bit CMC Data Address Byte 2 10 Bit CMC Data Address 7 183 0 15 191 0 6 182 0 14 190 0 5 181 1 13 189 0 4 180 0 12 188 1 3 179 1 11 187 0 2 178 0 10 186 0 1 177 0 9 185 0 0 176 0 8 184 0
A bit response of 1 means that the output is ON and a response of 0 means that the output is OFF.
Command 0F/Function 67 - PLC5 Typed Write

CAUTION

The CMC is treated as a PLC5 when this command is issued. This command writes data to the CMC starting at the specified data table address. You can write to a setpoint with either an integer or floating point number. Example: Presetting Analog Setpoints for 32-bit Values To write 105.4 PSIG as a floating point number to the user pressure setpoint (CMC data table address, 86h), issue the following command:
DLE 10 STX 02 DST 0D SRC 11 CMD 0F STS 00 TNS 81 CE FNC 67 Packet Offset 00 00 Total Trans 01 00 PLC5 System Address 07 00 0B 86
65
99
09
A 06
B 94 08 CD CC D2 42
DLE 10
ETX 03
BCC 93

DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 81 CE DLE 10 ETX 03 BCC 44
The difficulty in setting 32-bit values is determining the four data bytes for the number you want to send. The process required is ... 1. Determine the sign (positive = 0 or negative = 1). This is the first bit. 2. Divide the decimal value by 2 until the result is less than 2, but greater than 1. Count the number of iterations required. Add 127 to the number of iterations. This result is the exponent. Convert this result to binary. These are the next eight bits. 3. From the result obtained from step 2, subtract 1. Then, multiply this result by 2. If the result is less than 1, then the value of the first mantissa bit is 0. Otherwise, the mantissa bit is 1. If the result is greater than or equal to 1, then subtract 1 from the result and proceed with step 3 until the result is 0 or you have gone through this process 23 times. 4. Combine all 32 bits from the steps above and convert this value to hexadecimal. These 32 bits are the 4 hexadecimal data bytes needed for the command. As an example, we will start with the decimal value of 105.4. 1. Since this is a positive number, the first bit is 0. 2. Determine the exponent bits by ...
Iteration 1 2 3 4 5 6 Decimal 105.40000 52.70000 26.35000 13.17500 6.58750 3.29375 / / / / / / 2 2 2 2 2 2 = = = = = = Result 52.700000 26.350000 13.175000 6.587500 3.293750 1.646875
It took us six iterations to get the result to a number that is less than two and greater than or equal to one. Now, we must add 127 for an exponent of 133. Converting this to binary, the next eight bits are represented as 10000101. 3. Determine the mantissa bits by ...
66
Iteration 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Decimal 1.646875 1.29375 0.5875 1.175 0.35 0.7 1.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4

Operation Result - 1 * 2 = 1.29375 -1*2= 0.5875 *2= 1.175 -1*2= 0.35 *2= 0.7 *2= 1.4 -1*2= 0.8 *2= 1.6 -1*2= 1.2 -1*2= 0.4 *2= 0.8 *2= 1.6 -1*2= 1.2 -1*2= 0.4 *2= 0.8 *2= 1.6 -1*2= 1.2 -1*2= 0.4 *2= 0.8 *2= 1.6 -1*2= 1.2 -1*2= 0.4 *2= 0.8 Bit 1 0 1 0 0 1 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0
From the table above, 10100101100110011001100 represent the next 23 bits. 4. Combining the bits in sign, exponent and then mantissa order ... 0100-0010-1101-0010-1100-1100-1100-1100 This converts to 42-D2-CC-CC in hexadecimal. To conform to DF1 floating point format, the bytes are swapped as CC-CC-D2-42. Example: Presetting a 16-bit Integer and 16-bit Fraction Analog Setpoint To change the integer and fraction value for the user pressure setpoint to 105.4 PSIG, issue the command below. The integer portion of the number 105 (00-69h) and the fraction 0.4 is converted to 4000 (0F-A0h). These four bytes are placed in field B in the order of (6900-A0-0F).
DLE 10 STX 02 DST 0D SRC 11 CMD 0F STS 00 TNS 41 D0 FNC 67 Packet Offset 00 00 Total Trans 02 00 PLC5 System Address 07 00 0B 86
A 99 09 05 42 69 00
B A0 0F
DLE 10
ETX 03
BCC C0

DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 41 D0 DLE 10 ETX 03 BCC 82

Example: Forcing a Coil Forcing a single coil to either ON or OFF. Refer to the table below for each coil supported by the UCM-DF1 interface. An integer value of one or greater forces the coil to be ON. An integer value of zero forces the coil to be OFF.
CMC Data Table Address (decimal) 220 221 222 223 224 225 CMC Data Table Address (hex) DC DD DE DF E0 E1 Coil Name (Write only) Remote Acknowledge Remote Reset Remote Load Remote Unload Remote Start Remote Stop
67
NOTE For the CMC, forcing the above listed coils OFF is not meaningful because the default state of each of the above coils is OFF. When using these commands, they should be sent once (momentary) and the CMC will execute the commands.
NOTE The Forcing Coil command will override the CMC's current state. The forced state will remain valid until the CMC next solves the coil. The coil will remain forced if it is not programmed in the controller's logic.
CAUTION
For all of the Remote Coils, the compressors REMOTE COMMUNICATIONS ENABLED selection must be in the ENABLED position for these commands to execute. When DISABLED, the CMC ignores these coils being forced ON. The REMOTE COMMUNICATIONS ENABLED selection is typically located on the Settings tab of the Compressors Control Panel operator user interface. To remotely acknowledge the compressors alarm or trip condition, the following command is issued:
DLE 10 STX 02 DST 0D SRC 11 CMD 0F STS 00 TNS E1 F8 FNC 67 Packet Offset 00 00 Total Trans 01 00 PLC5 System Address 07 00 0B DC
A 99 09 03 42 01
B 00
DLE 10
ETX 03
BCC BC
The response from this command is: 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004
68
DLE 10 STX 02 DST 11 SRC 0D CMD 4F

STS 00 TNS E1 F8 DLE 10 ETX 03 BCC BA
The following command works the same:

DLE 10 STX 02 DST 0D SRC 11 CMD 0F STS 00 TNS 41 E3 FNC 67 Packet Offset 00 00 Total Trans 02 00 PLC5 System Address 07 00 0B DC
A 99 09 05 42 01 00
B 00 00
DLE 10
ETX 03
BCC 6E

DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 41 E3 DLE 10 ETX 03 BCC 6F
Example: Forcing Multiple Coils Forces each coil in a series of contiguous coils to either ON or OFF. Refer to the data table above for a coil list supported by the UCM-DF1 Interface. NOTE The Forcing Multiple Coils command will override the CMCs current state. The forced state will remain valid until the CMC next solves the coil. The coil will remain forced if it is not programmed in the controller's logic.
To force a reset (CMC data table address, DDh) and start (CMC data table address, E0h) of the compressor the following command is sent:
DLE 10 STX 02 DST 0D SRC 11 CMD 0F STS 00 TNS 21 0C FNC 67 Packet Offset 00 00 Total Trans 08 00 PLC5 System Address 07 00 0B DD
A 99 09 11 42 01 00 00 00 01 00 00 00
B 01
00
00
00
01
00
00
00
DLE ETX 10 03
BCC 4F

DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 21 0C DLE 10 ETX 03 BCC 66
The number of contiguous coils is four (DD, DE, DF, and E0h). The message length of integer elements is 8 and the number of data bytes in field B is 16.
Command 0F/Function A2 - SLC Typed Logical Read

The CMC is treated as an SLC5/04 when this command is issued. This function reads a block of data from CMC starting at a specified data table address. Example: Reading an Analog Value To read the pressure setpoint (CMC data table address 86h) as a floating point number, the following command is issued:
DLE STX DST SRC CMD STS TNS FNC Byte Size File No. File Type Ele No. S/Ele No. DLE ETX BCC

10 02 0D 0B 0F 00 D4 19 A2 04 0B 8A 86 00 10 03 2B
69

DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS D4 19 CD CC Data D2 42 DLE 10 ETX 03 BCC FF
The important command bytes are explained below:

Field Byte Size File Number File Type Element Number Description The number of data bytes to be read. Address files 0-255 only. For CMC, file 10 is designated for discrete only. File (11+N) is for the (N+1) th 256 entries in the CMC data table. 85h: bit 89h: integer 8Ah: float Address elements 0-255 only. The address byte format is the same as PLC5 for CMC. 254: (FE) 255: (FF-FF-00) Not used, always 00h.
Sub-Element Number
The four bytes in data field of the response message are converted to a floating point number, 105.4 PSIG. To read the pressure setpoint value as integer, the following command is sent:
DLE 10 STX 02 DST 0D SRC CMD STS 0B 0F 00 TNS D4 27 FNC Byte Size A2 04 File No. 0B File Type 89 Ele No. 86 S/Ele No. 00 DLE ETX 10 03 BCC 1E

DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS D4 27 69 00 Data A0 0F DLE 10 ETX 03 BCC 86
The first two bytes in data field represent the integer portion, 106 (00-69h), of the setpoint. The second two bytes represent the fraction portion, 4000 (0F-A0h), of the setpoint. Example: Reading Multiple Analog Values The following command reads analog inputs channels 3-9 as integer:
DLE 10
STX 02
DST 0D
SRC CMD STS 0B 0F 00
TNS D5 A9
FNC Byte Size 1C A2
File File No. Type 0B 89
Ele No. 03
S/Ele No. 00
DLE ETX 10 03
BCC 06

DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS D5 A9 63 00 5C 21 09 00 0F 0A Data 20 00 D6 00 62 00 E7 0B
00
00
FF
0B
2E
Data 00 66
14
BC
00
83
1E
DLE 10
ETX 03
BCC C0
70
Example: Reading Single Discrete Data After reviewing the Electrical Schematic for your compressor, you determine that the digital input for fan motor overload is located on J4-P5 (Channel 4). The CMC data table address is ADh for the input in question. Therefore, to read the state of the fan motor overload as a two byte integer, the following command is issued:
DLE 10 STX 02 DST 0D SRC CMD STS 0B 0F 00 TNS D6 79 FNC Byte Size 02 A2 File File No. Type 0B 89 Ele No. AD S/Ele No. 00 DLE ETX 10 03 BCC A5

DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS D6 79 Data 01 00 DLE 10 ETX 03 BCC 49
The data response (01) means that the input is ON, or the fan motor overload has tripped. Example: Reading 16 Bit-Packed Discrete Data To read 16 bit-packed discrete values for digital outputs as a two-byte integer, the following command is sent:
DLE 10 STX 02 DST 0D SRC CMD STS 0B 0F 00 TNS E1 41 FNC Byte Size 02 A2 File File No. Type 0A 85 Ele No. 0B S/Ele No. 00 DLE ETX 10 03 BCC 79
Note that the file number must be 10. The local data file used to store the returned data can be either bit (85h) or integer (89h) type. The response from this command is:
DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS E1 41 28 Data 10 10 DLE 10 ETX 03 BCC 3F
Please refer to the PLC5 Typed Read command section for the method to interpret the 16bit discrete values.
Command 0F/Function AA - SLC Typed Logical Write

The CMC is treated as a SLC5/04 when this command is issued. This command writes a block of data to CMC starting at a specified data table address. You can write to a setpoint with either an integer or floating point number. Example: Presetting Analog Setpoint for 32-bit Value To write 105.4 PSIG as a floating point number to the user pressure setpoint (CMC data table address, 86h), issue the following command:
DLE 10 STX 02 DST 0D SRC CMD STS 0B 0F 00 TNS E1 70 FNC Byte Size 04 AA File File No. Type 0B 8A Ele No. 86 S/Ele No. 00 Data CD CC D2 42 DLE 10 ETX BCC 03 12

DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS E1 70 DLE 10 ETX 03 BCC 48

Example: Presetting a 16-bit Integer and 16-bit Fraction Analog Setpoint To change the integer and fraction value for the user pressure setpoint to 105.4 PSIG, issue the command below. The integer portion of the number 105 (00-69h) and the fraction 0.4 is converted to 4000 (0F-A0h). These four bytes are placed in field B in the order of (6900-A0-0Fh).
DLE 10 STX 02 DST 0D SRC CMD STS 0B 0F 00 TNS E1 82 FNC Byte Size 04 AA File File No. Type 0B 89 Ele No. 86 S/Ele No. 00 Data 69 00 A0 0F DLE 10 ETX BCC 03 96
71

DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS E1 82 DLE 10 ETX 03 BCC 36
Example: Forcing a Coil Forces a single coil to either ON or OFF. Refer to the CMC data table for each coil supported by the UCM-DF1 interface. See the same example in the PLC5 Typed Write command section for more details. To remotely acknowledge the compressors alarm or trip condition, the following command is issued:
DLE 10 STX 02 DST 0D SRC CMD STS 0B 0F 00 TNS E1 A3 FNC Byte Size AA 04 File No. 0B File Type 89 Ele No. DC S/Ele No. 00 Data 01 00 00 00 DLE 10 ETX BCC 03 36

DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS E1 A3 DLE 10 ETX 03 BCC 15
To remotely acknowledge the compressors alarm or trip condition, the following command works the same:
DLE 10 STX 02 DST 0D SRC CMD STS 0B 0F 00 TNS E1 AD FNC Byte Size AA 02 File No. 0B File Type 89 Ele No. DC S/Ele No. 00 Data 01 00 DLE 10 ETX BCC 03 2E

DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS E1 AD DLE 10 ETX 03 BCC 0B
Example: Forcing Multiple Coils Forces each coil in a series of contiguous coils to either ON or OFF. Refer to the CMC data table for a list of coils supported by the UCM-DF1 interface. To force a reset (CMC data table address, DDh) and start (E0h) of the compressor, the following command is sent:
DLE 10 STX 02 DST 0D SRC CMD STS 0B 0F 00 TNS E2 3A FNC AA Byte Size 10 10 File No. 0B File Type 89 Ele No. DD S/Ele No. 00 Data 01 00 00 00 01 00 00 00
Data 01 00 00 00 01 00 00 00
DLE 10
ETX 03
BCC 8E
NOTE 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004
72

The byte size value 10h is transmitted as 10h 10h to be distinguished from the control character DLE.

DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS E2 3A DLE 10 ETX 03 BCC 7D
The number of contiguous coils is four (DD, DE, DF, and E0h). The assigned local message buffer length is 8 integer elements, which is 16-byte long.
Allen-Bradley SLC 504 Example

Data Files RSLogix 500 Ladder Diagram
The following ladder logic example is the fastest and most reliable method for gathering data from a CMC.

First Pass S2:1 0000 15 MSG Read/Write Message Peer-To-Peer Type Read Read/Write 500CPU Target Device Local Local/Remote N7:0 Control Block 14 Control Block Length Setup Screen N7:0 0002 12 N7:0 0003 13 10 MSG Read/Write Message Peer-To-Peer Type Read Read/Write 500CPU Target Device Local Local/Remote N7:20 Control Block 14 Control Block Length Setup Screen N7:20 10 N7:0 13 N7:20 10 N7:0
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N7:0 U 15
0001
EN DN ER
N7:0 U 15
EN DN ER
N7:20 0004 12 N7:20 0005 13 0006
N7:20 U 15 N7:0 U 15 END
UCM STS Error Codes

STS Code (hex) 00 10 30 3F D0 E0 Definition Success - no error Illegal command or function Remote node host is missing, disconnected, or shutdown Illegal CMC data address or count Illegal data type Cannot form CMC data table query/set list
NOTE The UCM-DF1 driver does not support EXT STS. According to Allen-Bradley DF1 protocol convention, EXT STS is part of the message only if STS = F0h.
74

When the CMC receives a DF1 command without any communication error and the command is executed successfully, a normal response with status code 00h is returned. If the UCM does not receive the command due to a communication error, no response is returned and the command initiator will eventually time out. If the UCM does receive the command, but detects error (invalid BCC/CRC...), control characters DLE NAK is returned to the command initiator, which in turns retransmits the command message and restarts a time out to wait for the response. This can be repeated a few times depending on the limit preset for retransmission. Once the limit is exceeded, the command initiator is informed of the failure and proceeds to the next command. If the time out expired before a response is received, the command initiator sends out DLE ENQ control characters to request a retransmission of the last response. It restarts a time out and wait for the response. There is a limit on the number of inquiries allowed per command message. When this limit is exceeded, the command initiator proceeds to the next command. When UCM receives DLE ENQ or DLE NAK message, it resends the last response to the command initiator. When DLE ACK message is received by the UCM, no response is returned. When the UCM receives a command without any communication error, but cannot handle it, the UCM will return an exception response with the appropriate status code informing the command initiator of the nature of failure. NOTE The table below explains the meanings of different control symbols for DF1 protocol:
Control Symbol DLE ACK DLE NAK DLE ENQ
Definition a message frame has been successfully received a message frame was not received successfully request retransmission of a response from the destination node
Communication Parameters
Configuration of the UCM RS-422 ports communication speed (baud rate), parity, number of data bits, number of stop bits... is available through the Ingersoll-Rand Service Tool for the UCM and will be configured by a certified Ingersoll-Rand Service Representative. The settings should be the same as the 1770-KF2 interface module.
Network Setup
The network diagram that follows depicts the communication interface between AllenBradley DF1 network and Ingersoll-Rand CMC Microcontroller. The 1770-KF2 always acts as a slave. The slave cannot initiate a command; i.e., the UCM cannot initiate a command over DH+ network. It only returns response messages to queries that are addressed to them individually. Broadcast is not supported over the DF1 network.
75
CMC Panel
CE N T A C Microcontroller
RS-232 Network for Operator User Interface, Twisted Pair Wires with Common (3 Wires) Serial Port (COM1)
Base Control Module (BCM)
IRBUS (RS-485) Network for Base Control Modules and Universal Communication Modules, Twisted Pair Wires with Ground (3 Wires)
IN G ER S O L L -R A N D Service Tool
IRBUS Address: 1
470 ohm
IRBUS IN (For IR Use) IRBUS OUT (For IR Use)
Service Tool Plug on Panel Door
Universal Communication Module (UCM) IRBUS Address 4
IRBUS Address: 2
Network Card Comm Port on Server IN G ER S O L L -R A N D Air System Controller (ASC)
Cat5 Cable
Universal Comm. Module (UCM) IRBUS Address 5 Universal Comm. Module (UCM) IRBUS Address 6
Next CMC Panel(s) for use in ASC
Modbus Network #1 Full or Half Duplex RS-422 or RS-485
Ethernet to Modbus Bridge To DH+ Network Allen-Bradley 1770-KF2 Interface Module
DF1 Network Full Duplex RS-422A
76 1770-KF2 Setup
A 1770-KF2 module links asynchronous devices (RS-422A or RS-232C) to an AllenBradley Data Highway or Data Highway Plus network. The 1770-KF2 module has 8 switch assemblies that let you select various communication options. The switch assemblies are shown in the diagram below:
Switch Assembly SW-1 SW-2, SW-3, SW-4 SW-5 SW-6 SW-7 SW-8 Communication Option Asynchronous link features Node number Network link communication rate Asynchronous link communication rate DH/DH+ network link section RS-232C/RS-422A selection
CAUTION
The 1770-KF2 module reads the status of these communication option switches only at power up, so you need to change switch settings with 1770-KF2 powered off.
SW-1 (Asynchronous Link Features)

The following table shows the different combinations available for setting the asynchronous link with the 5 dipswitches of SW-1.
SW-1 Settings 3 (Duplicate Message) ON: ignore OFF: accept OFF OFF OFF OFF OFF
Protocol
Error Check
Parity
Embedded Response
4 (Hand Shake) OFF OFF OFF OFF OFF
Full Duplex Full Duplex Full Duplex Full Duplex Full Duplex
BCC BCC BCC BCC CRC
None Even None Even None
No No Yes Yes Yes
OFF ON OFF ON OFF
OFF OFF ON ON ON
OFF OFF OFF OFF ON
CAUTION
Only the UCM-DF1 driver supports the full duplex options. Half duplex is not supported.
SW-2, SW-3, SW-4 (Node Address)

These three switch assemblies are used to set the network node number of the 1770-KF2 module. Set both switches in SW-2 OFF for DH+ link because the node number should be a 2-digit octal number that identifies the 1770-KF2 as a unique node on DH+. Valid node numbers for 1770-KF2 in DH+ network are 00 to 77 octal. 80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004

First digit (SW-2) should always be set to zero.
SW-2 Setting 1 2 OFF OFF OFF ON ON OFF ON ON Digit 0 1 2 3
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Second and third digits:

1 OFF OFF OFF OFF ON ON ON ON SW-3, SW-4 Setting 2 OFF OFF ON ON OFF OFF ON ON 3 OFF ON OFF ON OFF ON OFF ON Digit 0 1 2 3 4 5 6 7
SW-5 (Network Link Communication Rate)

Switch assembly SW-5 lets you select the communication rate for the 1770-KF2 modules network link (DH+). Set both switches ON for a network communication rate of 57,600 bits per second. Be sure to set all modules on the same DH+ network for this communication rate.
SW-6 (Asynchronous Link Communication Rate and Diagnostic Commands)

Switches #1, #2, #3 of SW-6 let you select the communication rate for the 1770-KF2 modules asynchronous port. Meanwhile, switch #4 determines how 1770-KF2 module treats diagnostic commands sent by a remote DH+ node. It is recommended to set at 9600 baud or higher, and execute received diagnostic commands.
SW-6 Setting 4 ON OFF
Execute received diagnostic commands Pass any received diagnostic commands to the attached asynchronous device
The available baud rate settings are shown below:

Baud Rate (Bits per second) 110 300 600 1200 2400 4800 9600 19200 1 OFF ON OFF ON OFF ON OFF ON SW-6 Setting 2 OFF OFF ON ON OFF OFF ON ON 3 OFF OFF OFF OFF ON ON ON ON
SW-7 (Network Link Selection)

UCM only supports DH+ network. SW-7 should always select DH+.
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Network Mode DH DH+

SW-7 Setting 1 2 OFF OFF ON OFF
SW-8 (RS-232C/RS-422A Selection)

The UCM-DF1 interface uses RS-422 communication. SW-8 should select RS422.
Communication Type RS-232C RS-422A SW-8 Setting 1 2 OFF ON ON OFF
Wiring Diagram for RS-422A

1770 KF2 Module RS-422 1 14 25 16 18 4 5 6 8 20 GND TX+ TXRX+ RXCable not to exceed 4000 feet UCM RS-422 RX+ RXTX+ TX-
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Documentation
An Electrical Schematic drawing is provided as standard after order placement. Control Panel Outline drawings are optional. Logic diagrams are considered proprietary and are not available.
System Information
Status Codes
The following table lists the status codes for the Base Control Module (BCM) and the Operator User Interface (OUI). These codes indicate every operating condition, both normal and abnormal, for the system. A code always exists for the system; for example, Status 05h indicates that the system is running properly. These codes, except Status 00h and 05h, are shown on a blank screen in the upper left hand corner of the Operator User Interface (OUI). Since Status 00h and 05h are normal operating conditions, these codes are not displayed. When a code is displayed, contact your local Ingersoll-Rand Service Representative.
Status Code 00h 01h Definition Booting Stay In Boot Comments The BCM is in the boot process. This is a normal process during BCM power up. This state will not be displayed. The BCM is held in boot mode by the hardware configuration. This condition exists only when the boot jumper (hardware device) is plugged into the display (OUI) port. This hardware jumper is only required when doing system level reprogramming of the module. The BCM software is not valid. This condition occurs when the CRC (Cyclic Redundancy Check) calculated by the module does not equal the CRC value written to the module when programmed. This would typically occur when the programming process is aborted (halted). The module must be reprogrammed. The BCM is currently in the process of being programmed. If this message does not disappear after programming is completed, power cycle the unit. The BCM software has failed to operate properly. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. Normal operating condition. This state will not be displayed. Operating system error. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. Operating system error. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. The BCM application software and tables are not compatible. The module must be reprogrammed. Analog input system error. A hardware malfunction has occurred. Analog output system error. A hardware malfunction has occurred. Digital input and output system error. A hardware malfunction has occurred. Ladder logic processing system or loop task error. The module must be reprogrammed. Comparator system error. The module must be reprogrammed. Operator User Interface system error. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. Data logging system error. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. Power supply voltage (+24 VDC) dropped below minimum operating level. Check power supply. Cycle power when voltage is within proper operating limits. Once restarted, the program will operate properly until the same condition reoccurs.
02h
ROM CRC Failed
03h 04h 05h 06h 07h 08h 09h 0Ah 0Bh 0Ch 0Dh 0Eh 0Fh 10h
Commanded To Boot Invalid Application Application Running Fatal Exit System Error Incompatible Software Versions A-D System Error D-A System Error Digital I/O System Error Logic Engine System or Loop Task Error Comparator System Error Operator User Interface Error Data Logging System Error Low Power
80
Status Code 11h 12h 13h 14h 15h 16h 17h 18h
Definition Task Overrun Watchdog Failure Intermodule Data Error Calculation Block Error Interpolation System Error Calibration System Error String System Error Incompatible Hardware
Comments System processing capabilities do not meet requirements for operation. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. The internal backup system monitor is not operational. BCM hardware should be replaced. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. An error has occurred while generating a message to be sent from one BCM to the other BCM in a multi-module configuration. The module must be reprogrammed. A stack underflow or overflow has occurred in a calculation block. The module must be reprogrammed. An error has occurred in the interpolation block. The module must be reprogrammed. Occurs during initialization of the EEPROM block. The module must be reprogrammed. Occurs when string system table is invalid and/or when application is invalid. The module must be reprogrammed Occurs when trying to run v2.xx software on v3.xx hardware. Change hardware or software.
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Module Layout
J15-Digital Outputs, Channels 4-1 J14-Digital Outputs, Channels 8-5 J13-Digital Outputs, Channels 12-9 J12-Digital Outputs, Channels 16-13
Pin 1 Pin 1 Pin 1 Pin 1
J10-Power Input (24 VDC)
Pin 1
J9-Current Transformer Input (0-5 Amps) J8-Speed Sensor Input (1-150 Hz)
Pin 1
F102-Fuse for AnalogI/O (J1, J2 and J3) F103-Fuse for Digital Inputs (J4 and J5)
F101-Fuse for Operator User Interface (Display) F100-Fuse for Base Module CPU Card
J7-RS485 Serial Data Link (IRBUS) J7-RS232 Serial Data Link (Display),
Pin 1
Pin 4
All Fuses are 5x20mm, GMA 1.5 amp, Fast Blow
J6-RS232 Serial Data Link (Display), Female DB9 J5-Digital (Discrete) Inputs (24 VDC), Channels 9-16
Pin 1
J4-Digital (Discrete) Inputs (24 VDC), Channels 1-8

Pin 1
J3-Analog Outputs (4-20mA) Channels 1-4

Pin 7 Pin 1 Pin 5 Pin 1
Pin 25 Pin 1
J1-Grounded Analog Inputs, (4-20mA) Channels 3-23
J2-Floating Analog Inputs, (4-20mA) Channels 1-2
82
Connector Description
Tag J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J12 J13 J14 J15 Type Grounded Analog Inputs, 4-20 mA Floating Analog Inputs, 4-20 mA Analog Outputs, 4-20 mA Digital (Discrete) Inputs, 24 VDC RS232 Serial Data Link (Operator User Interface) RS232 Serial Data Link (OUI) RS485 (IRBUS) Serial Data Link Speed Sensor Input, Variable Reluctance Current Transformer Input Power Digital Outputs Channel 3-23 1-2 1-4 1-8 9-16 na na Module Connector (12) Phoenix MDSTB 2, 5/2-G-5, 08 (2) Phoenix MDSTB 2, 5/2-G-5, 08 (3) Phoenix MDSTB 2, 5/2-G-5, 08 Phoenix MSTBA 2, 5/10-G-5, 08 9 Position D Sub Miniature (Female) Phoenix MSTBA 2, 5/9-G-5, 08 Phoenix MSTBA 2, 5/3-G-5, 08 Terminal Strip Phoenix MSTBA2, 5/5-G-5, 08 (4) Phoenix MSTBA 2, 5/8-G-5, 08 Mating Connector (2) Phoenix MDST 2, 5/24-3T-5, 08 (2) Phoenix MDST 2, 5/4-3T-5, 08 (2) Phoenix MDST 2, 5/6-3T-5, 08 Phoenix MSTB 2, 5/10-ST-5, 08 9 Position D Sub Miniature (Male) Phoenix MSTB 2, 5/5-ST-5, 08 Phoenix MSTB 2, 5/3-ST-5, 08 Wire Lugs Phoenix MSTB 2, 5/5-ST-5, 08 (4) Phoenix MSTB 2, 5/8-ST-5, 08
na na 13-16 9-12 5-8 1-4
NOTES: 1. BCM Weight: 1775 177g [3.92 .39 lb.] 2. BCM Size: Length=355.6 mm [14.0 in] x Width=247 mm [9.7 in] x Depth=45 mm [1.8 in] 3. To ensure chassis ground, install 12-gauge ground strap between this module and the NEMA enclosure. Place external tooth lock washer between this module and the ground strap. 4. na is defined as not applicable. 5. All Phoenix connectors may be replaced with an equal supplier.

Connector Input and Output (I/O)
Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Pin 1 2 3 4 5 6 7 8 J1-Grounded Analog Inputs Analog Input Channel 3 Power 24 VDC, Channels 3 & 4 Shield, Channels 3 & 4 Analog Input Channel 4 Analog Input Channel 5 Power 24 VDC, Channels 5 & 6 Shield, Channels 5 & 6 Analog Input Channel 6 Analog Input Channel 7 Power 24 VDC, Channels 7 & 8 Shield, Channels 7 & 8 Analog Input Channel 8 Analog Input Channel 9 Power 24 VDC, Channels 9 & 10 Shield, Channels 9 & 10 Analog Input Channel 10 Analog Input Channel 11 Power 24 VDC, Channels 11 & 12 Shield, Channels 11 & 12 Analog Input Channel 12 Analog Input Channel 13 Power 24 VDC, Channels 13 & 14 Shield, Channels 13 & 14 Analog Input Channel 14 Analog Input Channel 15 Power 24 VDC, Channels 15 & 16 Shield, Channels 15 & 16 Analog Input Channel 16 Analog Input Channel 17 Power 24 VDC, Channels 17 & 18 Shield, Channels 17 & 18 Analog Input Channel 18 Analog Input Channel 19 Power 24 VDC, Channels 19 & 20 Shield, Channels 19 & 20 Analog Input Channel 20 Analog Input Channel 21 Power 24 VDC, Channels 21 & 22 Shield, Channels 21 & 22 Analog Input Channel 22 Analog Input Channel 23 Power 24 VDC, Channel 23 Shield, Channel 23 Spare Spare Power 24 VDC, Spare Shield, Spare Spare J2-Floating Analog Inputs Analog Input Channel 1+ Power 24 VDC, Channel 1 Analog Input Channel 1Shield, Channel 1 Analog Input Channel 2+ Power 24 VDC, Channel 2 Analog Input Channel 2Shield, Channel 2 Pin 1 2 3 4 5 6 7 8 9 10 11 12 Pin 1 2 3 4 5 6 7 8 9 10 Pin 1 2 3 4 5 6 7 8 9 10 Pin 1 2 3 4 5 6 7 8 9 Pin 1 2 3 4 5 6 7 8 9 J3-Analog Outputs Analog Output Channel 1+ Power 24 VDC, Channels 1 & 2 Analog Output Channel 1Analog Output Channel 2+ Shields, Channels 1 & 2 Analog Output Channel 2Analog Output Channel 3+ Power 24 VDC, Channels 3 & 4 Analog Output Channel 3Analog Output Channel 4+ Shields, Channels 3 & 4 Analog Output Channel 4J4-Digital Inputs Power 24 VDC, Channels 1-8 Digital Input Channel 1 Digital Input Channel 2 Digital Input Channel 3 Digital Input Channel 4 Digital Input Channel 5 Digital Input Channel 6 Digital Input Channel 7 Digital Input Channel 8 Ground, Channels 1-8 J5-Digital Inputs Power 24 VDC, Channels 9-16 Digital Input Channel 9 Digital Input Channel 10 Digital Input Channel 11 Digital Input Channel 12 Digital Input Channel 13 Digital Input Channel 14 Digital Input Channel 15 Digital Input Channel 16 Ground, Channels 9-16 J6-RS232 (Display) Not Used Receive Data (RxD) Transmit Data (TxD) Not Used Signal Ground Not Used Not Used Not Used Not Used J7-RS232 (Display) / RS485 (IRBUS) Receive Data (RxD) (Display) Transmit Data (TxD) (Display) Signal Ground (Display) Data Link 1+ (IRBUS) Data Link 1(IRBUS) Data Link Ground (IRBUS) Data Link 1+ (IRBUS) Data Link 1(IRBUS) Data Link Ground (IRBUS) Pin 1 2 3 Pin 1 2 Pin 1 2 3 4 5 Pin 1 2 3 4 5 6 7 8 Pin 1 2 3 4 5 6 7 8 Pin 1 2 3 4 5 6 7 8 Pin 1 2 3 4 5 6 7 8 J8-Speed Sensor SS+ SSSS Ground J9-Current Transformer CT+ CTJ10-Power Power +24V DC Power Ground Chassis Ground Display Power +24VDC Display Power Ground J12-Digital Outputs Digital Output Channel 16 Digital Output Channel 16 Digital Output Channel 15 Digital Output Channel 15 Digital Output Channel 14 Digital Output Channel 14 Digital Output Channel 13 Digital Output Channel 13 J13-Digital Outputs Digital Output Channel 12 Digital Output Channel 12 Digital Output Channel 11 Digital Output Channel 11 Digital Output Channel 10 Digital Output Channel 10 Digital Output Channel 9 Digital Output Channel 9 J14-Digital Outputs Digital Output Channel 8 Digital Output Channel 8 Digital Output Channel 7 Digital Output Channel 7 Digital Output Channel 6 Digital Output Channel 6 Digital Output Channel 5 Digital Output Channel 5 J15-Digital Outputs Digital Output Channel 4 Digital Output Channel 4 Digital Output Channel 3 Digital Output Channel 3 Digital Output Channel 2 Digital Output Channel 2 Digital Output Channel 1 Digital Output Channel 1
83
84
Operator User Interface Module (OUI)

Module Layout
Side View
J1-RS232 Port
Pin 1
J3-RS232/ RS485 Port
Pin 1
Pin 1
J2-Input Power
Tag J1 J2 J3 RS232 Port Input Power RS232/RS485 Port Type Module Connector 9 Position D Sub Miniature (Female) Phoenix MSTBA2, 5/2-G-5, 08 Phoenix MC 1.5/5G-3.81 Mating Connector 9 Position D Sub Miniature (Male) Phoenix MSTW2, 5/2-ST-5, 08 Phoenix MC 1.5/5ST-3.81
NOTES: 1. OUI Weight: 410 g [0.90 lb.] 2. OUI Size: Length=267 mm [10.5 in] x Width=175 mm [6.9 in] x Depth=60 mm [2.4 in] 3. All Phoenix connectors may be replaced with an equal supplier.

Pin 1 2 3 4 5 6 7 8 9 J1-RS232 Port No Connection Transmit (TX) Receive (RX) No Connection Signal Common No Connection No Connection No Connection No Connection Pin 1 2 J2-Input Power +12 To +24 VDC (VPOWER) Ground (GND) Pin 1 2 3 4 5 J3-RS232/RS485 Port RS232 Data Link Tx RS232 Data Link Rx Common (Com) IRBUS RS485 Data Link (DL+) IRBUS RS485 Data Link (DL-)

OUI PCB Assembly (Cover Removed) Showing replaceable fuse J1 9 Position "D" Sub Connector J3 5 Pin Connector
F2
85
Fast-Acting, SMF, .75A, 125V Littlefuse 0451.750 or 0453.750 or Equivalent
J2 2 Pin Connector
CMC User Interface/Bezel Cleaning Instructions

The following procedure is recommended to clean the CMC User Interface vinyl overlay material and/or the User Interface bezel. 1. Stop the compressor and depress the maintained Emergency Stop push-button, this will prevent an inadvertent start up or trip of the compressor during the cleaning process. 2. Dampen a soft cloth or paper towel with water and wipe any dust, dirt or liquids from the surface of the User Interface, do not use an abrasive pad or brush to clean the surface of the User Interface vinyl overlay or bezel. 3. If more aggressive measures are required to clean the User Interface and/or bezel surface use a mild non-abrasive household cleaner (such as Formula 409, Fantastik, etc.) sprayed or wiped directly onto the surface to be cleaned. Dampen a soft cloth or paper towel with water and wipe any remaining cleaner from the surfaces. Ingersoll-Rand Company recommends the following for cleaning the OUI and bezel: Cleaners: Water or mild household cleaner, no petroleum or acetone based fluids. Cleaning wipes: Soft cotton clothe or paper towels.
Backlight Replacement Procedure

Tools Needed: 1. Flat blade screwdriver with a small tip (1/8 inch) 2. Number 1 Phillips Screwdriver 3. Electrostatic Discharge Strap Connected to Earth Ground
86
Step 1
Step 2
J1
User Terminal
J3
Tx Rx COM DL+ DL-
User Terminal
Lift cover to remove

J2 Display Power
Remove cabling
Unplug connector and remove nylon cable retainer screws
Loo s
+ en scr ew s, s l
ide
righ
Step 3
Remove screws from the lower printed circuit board, then use a screwdriver to gently pry the backlight panel loose.
Step 4
Use circular stand-offs to rest screwdriver shaft against while prying backlight panel out.
The backlight is part of a larger panel that is removed as an assembly.
87
Step 5
Backlight panel is inserted into display between the circuit board and the LCD glass with the white plastic backing sheet and wires facing toward the circuit boards.
Step 6
Insert screws being careful not to over tighten.
Slide the backlight panel in place and align the screw holes so the screws may be inserted and tightened.
Route wiring, replace nylon cable retainers, insert backlight plug, replace main cover and connect power and communication cable to complete installation.
88
Universal Communication Module (UCM) Optional

Module Layout
Side View
J2-Service/Modem (RS232) Port J1-Microcontroller/Network (RS422/RS485) Port J3-Input Power
Pin 1
Pin 1
Pin 1
Top View
RS232 Activity Indicator
IRBUS RS485 Activity Indicator RS422/485 Activity Indicator
89
Tag J1 J2 J3 Type Microcontroller/Network (RS422/485) Port Service/Modem (RS232) Port Input Power Module Connector Phoenix MSTBA2, 5/8-G-5, 08 9 Position D Sub Miniature (Female) Phoenix MSTBA2, 5/2-G-5, 08 Mating Connector Phoenix MSTBW2, 5/24-ST-5, 08 9 Position D Sub Miniature (Male) Phoenix MSTW2, 5/2-ST-5, 08
NOTES: 1. UCM Weight: 410 g [0.90 lb.] 2. UCM Size: Length=136 mm [5.4 in] x Width=143 mm [5.6 in] x Depth=31 mm [1.2 in] 3. All Phoenix connectors may be replaced with an equal supplier.

Pin 1 2 3 4 5 6 7 8 J1-Microcontroller/Network Port IRBUS RS485 Datalink + (DL+) IRBUS RS485 Datalink - (DL-) Ground (GND) RS422/485 Transmit + (TX+) RS422/485 Transmit - (TX-) RS422/485 Receive + (RX+) RS422/485 Receive - (RX-) Ground (GND) Pin 1 2 3 4 5 6 7 8 9 J2-Service/Modem Port No Connection Transmit (TX) Receive (RX) No Connection Signal Common No Connection No Connection No Connection No Connection Pin 1 2 J3-Input Power +12 To +24 VDC (VPOWER) Ground (GND)
90
UCM Port Activity LEDs

The UCM has three light emitting diodes (LEDs) to indicate the activity of the RS232, RS422/485 and the IRBUS RS485 ports. The following table indicates the different states of these ports. RS422 RS485 off off on on on on blinking blinking off on off repeat IRBUS RS485 off off on blinking blinking on blinking on flash on off repeat
RS232 off on on on blinking blinking on on on on off repeat
UCM State No power (24 VDC) Boot mode, (cycle power to exit boot mode) Running, but no communication on any port Inter-module communication Service Tool in use Service Tool in use, but no response from BCM check connection between BCM and UCM MODBUS or DF1 communication in use RS-422 port in use, but no response from BCM check connection between BCM and UCM or Modbus and DF1 address This repeating action indicates a continuous reboot or application problem
Examples (Blinking indicates communication)
UCM Communications Parameters

The UCM has three communication ports, RS232, RS422/485 and IRBUS RS485. Each of these ports has its own communication parameters that it supports. Modbus/DF1 IRBUS RS-422/485 RS-485 4000 feet (1218.3 Meters) 100 feet (30.4 Meters) 300, 600, 1200, 2400, 38400 9600, 19200, 38400 Parity None None, Even, Odd None Data Bits 8 8 8 Stop Bits 1 1, 1.5, 2 1 Configurable No Yes* No * A certified Ingersoll-Rand Service Representative will provide this configuration. Parameter Distance Baud Rate Service Tool RS-232 50 feet (15.2 meters) 9600

RS422/485 Network Wiring Diagram - Full Duplex
91
SERVER (Modbus Master)

120 VAC
Compressor Panel #n
Modbus Address - nn IRBUS Address - any
To Server's Network Card
Ethernet Cable Cat5 or Better
Ethernet Switch
3 Com
Compressor Panel #6
120 VAC Modbus Address - 06 IRBUS Address - any
The maximum distance of a MODBUS Network is 4000 electrical feet; i.e., the length of the wire from the Ethernet Bridge (Location A) to the last compressor's Universal Communication Module (Location B). The maximum number of devices (nodes) on a MODBUS Network is 30. A terminating resistor is not required at the end of the network.
Compressor Panel #5
Rx- Rx+ Tx+ TxModbus Address - 05 IRBUS Address - any
Ethernet / Modbus Bridge

24VDC + Fused -
Compressor Panel #4
Modbus Address - 04 IRBUS Address - any
174 CEV 300
RS-422 2 Twisted Pair Wires with Ground (5 Wires)
Compressor Panel #3
RS-422 2 Twisted Pair Wires Plus Gnd. (5 Wires) Connect Ground One End Only
To Power Supply
To BCM
To Power Supply
To BCM
24+ Gnd Power
DL+ DL- Gnd Tx+ Tx- Rx+ Rx- Gnd RS-485 RS-422/485
RS-232 DB-9
RS-422 2 Twisted Pair Wires with Ground (5 Wires)
24+ Gnd Power
RS-232 DB-9
Universal Communication Module (UCM)
Modbus Address - 01 (Set through software)
Compressor Panel #1
Compressor Panel #2
92
RS422 Network Wiring Diagram - Half Duplex
SERVER (Modbus Master)

120 VAC
Compressor Panel #n
Modbus Address - nn IRBUS Address - any
To Server's Network Card
Ethernet Cable Cat5 or Better
Ethernet Switch
3 Com
Compressor Panel #6
120 VAC Modbus Address - 06 IRBUS Address - any
The maximum distance of a MODBUS Network is 4000 electrical feet; i.e., the length of the wire from the Ethernet Bridge (Location A) to the last compressor's Universal Communication Module (Location B). The maximum number of devices (nodes) on a MODBUS Network is 30. A terminating resistor is not required at the end of the network.
Compressor Panel #5
Rx- Rx+ Tx+ TxModbus Address - 05 IRBUS Address - any
Ethernet / Modbus Bridge

24VDC + Fused 174 CEV 300 A
Compressor Panel #4
RS-422 Twisted Pair Wires with Ground (3 Wires)
Compressor Panel #3
RS-422 Twisted Pair Wires With Ground (3 Wires) Connect Ground One End Only
To Power Supply
To BCM
24+ Gnd Power
RS-232 DB-9
RS-422 Twisted Pair Wires with Ground (3 Wires)
To Power Supply
To BCM
24+ Gnd Power
RS-232 DB-9
Compressor Panel #1
Compressor Panel #2

Terminating Resistor Modbus Network The RS422/485 circuitry built into each UCM supports Alternate-Fail-safe AC Termination. This termination circuitry enhances the UCM's ability to operation in harsher (electrically noisier) environments. Since this circuitry is built into the product, no external terminating resistor is required. For a thorough discussion of the various termination techniques, please refer to "A Comparison of Differential Termination Techniques", National Semiconductor Application Note 903 (AN-903), August 1993. This application note can be obtained from the Internet at "www.national.com".
93
Terminating Resistor IRBUS Network

Due to the data rate the RS485 IRBUS is provided with termination resistors mounted inside the panel. The value of each resistor is 470 ohms. The purpose of the termination is to prevent reflections. Reflections occur when a signal encounters different impedance and is reflected back towards the source. This can corrupt the intended data transmission. Where IRBUS is networked with other nodes two termination resistors are required, one at each end of the network.
94
Typical System Layout
Operator User Interface (OUI)

24 VDC Power RS232 Base Control Module (BCM) #1

470 ohm
IRBUS OUT IRBUS IN 24 VDC 120/240 VAC Power
IRBUS (RS485)
IRBUS (RS485)
Universal Communications Module (UCM)
Base Control Module (BCM) #2 24 VDC
Power Supply
Service Tool Port Not Shown
24 VDC Optional Equipment

Network Diagram
95
CMC Panel
RS-232 Network for Operator User Interface, Twisted Pair Wires with Common (3 Wires) Serial Port (COM1)
IRBUS (RS-485) Network for Base Control Modules and Universal Communication Modules, Twisted Pair Wires with Ground (3 Wires)
IN G ER S O L L -R A N D Service Tool
IRBUS Address: 1
470 ohm
IRBUS IN (For IR Use) IRBUS OUT (For IR Use)
Service Tool Plug on Panel Door
Universal Communication Module (UCM) IRBUS Address 4
IRBUS Address: 2
Network Card Comm Port on Server IN G ER S O L L -R A N D Air System Controller (ASC)
Cat5 Cable
Universal Comm. Module (UCM) IRBUS Address 5 Universal Comm. Module (UCM) IRBUS Address 6
Next CMC Panel(s) for use in ASC
Ethernet to Modbus Bridge
To next CMC Panel or any other Modbus compliant product
Glossary
The following glossary is generic; therefore, some terms do not apply to all CMC systems.
AB See Allen-Bradley. Absolute Address For Modbus compliant devices, the specific memory location for a coil, discrete input, register or analog input. The address is a five-digit number. Address This term is used by PLC manufacturers to indicate a specific memory location within the unit. These locations typically reference the value for data items like analog inputs, analog outputs, digital inputs, digital outputs, coils and intermediate computational states. Through these memory locations, the current system pressure, first stage pressure and discharge air temperature can be determined. Alarm The term used to indicate that an abnormal condition exists that should be addressed by an operator. This condition has not reached a level that would shut down the compressor. Alert See Alarm. Allen-Bradley A manufacturer of control products, most notably PLCs. These PLCs are used for various industrial applications including controlling compressors. American Wire Gage (AWG) The measurement system used to indicate the diameter of the wire. The gage number increases as the wire diameter decreases. Analog Input An electrical device, which represents a specific real world pressure or temperature. As these items fluctuate, the electrical signal to and from the microprocessor board also fluctuates proportionally to the amount of change. The electrical signal is typically in the form of a current that ranges from 4 to 20 milli-amps in magnitude. Baud Rate Unit of signaling speed for data communications. The speed in baud is the number of line changes (in frequency, amplitude, etc.) or events per second. At low speeds each event represents only one bit and baud rate equals bits per second. As speed increases, each event represents more than one bit, and baud rate does not truly equal bits per second. BCM Base Control Module. The device of the CMC that receives all of the compressor inputs and outputs and makes decisions about how the compressor is to operate. Binary Signal The type of signal used in communications. Binary refers to the smallest size of data being transmitted, a bit. BPS Bits per second. Unit of signaling speed for data communications. Bridge A device which forwards traffic between network segments based on data link layer information. These segments would have a common network layer address. CAT 5 Category 5. A classification of cable used in twistedpair networks.
CE Mark The CE Mark is a combination of various individual European standards into one set of standards for the entire European community. The Mark is a self declaration and self marking process. Once you have proven that the particular equipment meets the requirements of CE Mark and have the data to back it up, you may mark the product with the CE Mark. Citect One of many SCADA software packages that can be used for air system integration. Circuit Breaker An automatic switch that stops the flow of electric current in a suddenly overloaded or abnormally stressed electric circuit. CMC Centac MicroController. CMC System Any combination of CMC control components which when combined create a control system. The typical CMC system consists of a Base Control Module (BCM), Operator User Interface (OUI), and Power Supply (PS). A common variation on the typical system is the addition of a Universal Communications Module (UCM). Coast Timer The time interval, in seconds, between a compressor stop or trip and the motor coming to a complete stop. The timer is used to inhibit restarting. Compressor Load, Load The power consumption of the compressor. It is typically indicated in amps, kilowatts, SCFM, etc. COM Port See Serial Port. Control Transformer The transformer that is used to reduce the incoming voltage approximately 120 volts for controlling the CMC electrical devices (relays, power supply, etc.). CSA Approval Canadian Standards Association approval is required for all electrical devices shipped into Canada. This association is similar to UL for the United States and CE for Europe. Daisy Chain A method of wiring a communication network. This method starts with the master and it is wired directly to compressor #1. Compressor #2 is wired to compressor #1, then compressor #3 is wired to compressor #2. Data Link A direct serial data communications path between two devices without intermediate switching nodes. Data Highway Plus A communication protocol used by Allen-Bradley PLC 5 and SLC500 PLCs. DCS See Distributed Control System. degC Degrees Celsius, Centigrade. degF Degrees Fahrenheit. DH+ See Data Highway Plus. Digital Device A device, which is either on or off; e.g., the N.C. contact on the seal air switch. Discrete Device See Digital Device. Discharge Pressure The gas pressure between the last stage of compression and the check valve.

IRBUS The proprietary communication protocol used to communicate to and from one or many Base Control Modules (BCM), Universal Communication Modules (UCM) and Operator User Interfaces (OUI). Loopback A diagnostic test in which a transmitted communication signal is returned to the sending device after passing through all or part of the communication network. This test compares the transmitted signal to the received signal. The test passes if the signals are identical. MA, mA Milliampere Maintained Contact A contact closure that remains closed. MMI Man Machine Interface. The term used to indicate the device or method used for a human to interface with a machine. Typically these interfaces are LCD displays or computer screens. For the CMC, the MMI is the Operator User Interface (OUI). Modbus A sixteen-bit communication protocol originally developed for Modicon PLCs. This protocol has become a defacto standard for industrial equipment. Modicon A PLC brand name manufactured by Schneider Automation. Momentary Contact A contact closure that closes and then opens. N.C. Normally Closed. Used to indicate the state of a contact when no power is applied. N.O. Normally Open. Used to indicate the state of a contact when no power is applied. NEMA National Electrical Manufacturers Association. Network A series of points, nodes or devices connected by some type of communication medium. Offset On a Transmitter this adjustment sets what is in effect the value of output when the input is zero. On-Line/Off-Line Control mode that allows the system discharge pressure to fluctuate between two pressure setpoints. The compressor will load when the actual pressure is below the lower setpoint pressure and will unload when it reaches the higher setpoint pressure. OUI Operator User Interface. The device on the CMC that gathers user inputs and provides compressor operating status. Parity The addition of non-information bits to make up a data transmission block that ensures the total number of 1s is either even (even parity) or odd (odd parity). This is used to detect errors in communication transmission. Password The four digit parameter used to determine when the user can modify setpoints. The range of this password is 0000 to 9999.
Distributed Control System A system that attempts to control an entire plant or process with multiple independent local controllers by networking these local controllers to a central computer through digital communications. These central computers can be a PC, PLCs or other larger systems. Some manufacturers of these DCS products are Bailey, Honeywell, Allen-Bradley, Siemens, and others. Drain Wire An insulated wire in contact with a shield throughout its length, and used for terminating the shield. Dry Contacts A set of contacts that require a power source supplied by others (customer). This is the normal type of contacts that we provide. ERAM Erasable Random Access Memory. Event The control transfer or rule(s) as used in State Logic to transfer from one state to another. FactoryLink One of many SCADA software packages that can be used for air system integration. FLA Motor Full Load Amps. The motor amperage at full load, this value is found on the motor nameplate. Flexible Conduit Small diameter hose, made of plastic coated aluminum, which is used to enclose wire from the control panel to machine mounted instruments. Fused Disconnect As a safety precaution, this option removes power from the panel before the door is opened. By turning the rotary door handle, the panel power is terminated. The disconnect would have to be mounted external to the panel enclosure. The short circuit capacity, maximum ground fault, motor full load amps, motor locked rotor amps and motor voltage must be known to size the disconnect properly. Ground A connection to earth or to some extended conducting body that serves instead of the earth. Ground Loop An unwanted, continuous ground current flowing back and forth between two devices that are at different ground potentials. Grounded System An electrical system in which at least one point (usually a wire) is intentionally grounded. I/O See Input/Output. IEC International ElectroTechnical Commission is the governing body of Europe for electrical equipment and codes. Input/Output The hardware interface between the compressor and the control system. This term generically applies to the entire interface circuit including sensor, wiring, and junction points. Intellution One of many SCADA software packages that can be used for air system integration. Interface The hardware or software device used to communicate between products. Interlock An electrical function that prevents the compressor from starting in the event that the function has not been satisfied.

PLC Programmable Logic Controller. This hardware device is configurable such that many types of analog and digital inputs and outputs can be utilized to control various industrial products. PLC 5 Type of Allen-Bradley PLC used for large applications. PROM Programmable Read Only Memory. Protocol A formal set of conventions governing the formatting and relative timing of message exchange between two communication systems. RAM Random Access Memory. Range The region between the limits within which a quantity is measured, received or transmitted expressed by stating the Lower and Upper Range Limits. Relative Address For Modbus compliant devices, the fourdigit address within the range of 0-9999. The relative address can be determined from the absolute address by deleting the type (the ten-thousandth place) and subtracting one. Rigid Conduit Small diameter pipe, made of carbon steel with welded connections, which is used to enclose wire from the control panel to machine mounted instruments. This conduit is typically used in hazardous area classifications. RS-232 Electronic Industries Association interface standard between data terminal equipment and data communication equipment, using serial binary data interchange. This is the most common standard used by industry. RS-232 to RS-422/485 Converter A hardware device that electrically converts an RS-232 signal into an RS-422 or RS485 signal. RS-422 Electronic Industries Association interface standard that specifies electrical characteristics for balanced circuits and extends transmission speed and distances beyond RS-232. This standard is a balanced voltage system with a high level of noise immunity. RS-485 Electronic Industries Association balanced interface standard similar to RS-422, but uses a tri-state driver for multidrop applications. RTD Resistance Temperature Detector. An instrument that measures temperature by detecting the voltage across the RTD material (mostly platinum). The temperature is determined because as the temperature increases the resistance increases. RTU Remote Terminal Unit. A device typically used for data acquisition to gather data. By using this definition, the Base Control Module is an RTU. SCADA Supervisor Control and Data Acquisition. The generic classification for software that gathers data for control of industrial products. Sequencer A hardware or software device that controls the order in which compressors starts, stops, loads and unloads. Some sequencers also control loading and unloading through incremental pressure setpoints among the compressors. For example, in a three-compressor application the setpoints may be 101 psi for compressor #1, 100 psi for compressor #2 and 99 psi for compressor #3. Assuming the pressure transducers were calibrated within one psi of each other and the machines were running unloaded, this configuration would drive compressor #1 to load first when the pressure dropped to 101 psi. Serial Device A Personal Computer (PC), Programmable Logic Controller (PLC), Distributed Control System (DCS) or any other device that can transmit, receive and interpret an RS422/485 formatted signal. Serial Port The RS-232 connection on the back of a PC to communicate with other equipment. This connection is typically referred to as COM1. A single PC can have more than one serial port. Service Tool The software used on the PC to configure, tune, record and log data from the CMC. Service Tool Plug A port on Panel door to provide access to IRBUS Network. Requires Laptop and external UCM. Shielded Wire Wire that has a sheet, screen or braid of metal, usually copper, aluminum, or other conducting material placed around or between electric circuits or cables or their components, to contain any unwanted radiation, or to keep out any unwanted interference. SLC500 Type of Allen-Bradley PLC used for relatively small applications and is lower in cost than an equivalent PLC 5. Span The algebraic difference between the Lower and Upper Range Limits. Start Timer The time interval, in seconds, between pressing the Start button and the compressor is running at full speed. The timer is used to transition wye delta starters, inhibit loading. State A task that is currently being executed in State Logic. Only one state is active at one time. State Logic State Logic is an alternative to traditional control languages used for machines, systems, and processes. State Transition The movement from one state to another based on one or more events. Status Bar The Status Bar provides four distinct types of information (Compressor Operating State, Compressor Status, Compressor Control Location and Page Number). This region is always visible from any folder and page combination. Switch, Ethernet A device connected to several other devices. Transfers messages across the network.
Terminal Block A device that is used to connect to wires. Typically, these blocks are provided for customer field wiring to the panel and when one wire is to be connected to multiple devices.

Zero The value representing a measured value of zero. Equals the Lower Range Limit only when the Range is zero starting. Z-Purge Required when the customer environment is Division 2. A Type Z Purge reduces the classification within an enclosure from Division 2 too non-hazardous. When provided, a NEMA 4 or NEMA 4X enclosure is required. Hand valve selectable quick and slow purges, with flow meters are provided to regulate the amount of gas entering the panel. A differential pressure switch is wired to a light on the front of the panel to indicate if there is a loss of purge gas. A relief valve is installed to prevent over-pressurization and a warning label, text below, is affixed to the front of the panel.
Terminating Resistor A resistor placed at the end of a communication network for absorbing or sufficiently attenuating signals incident on it so that they are not reflected back into the transmission line at amplitudes where they would cause distortion of the data signal. Typically, a resistor is placed at each end of the network to help eliminate noise. Thermocouple A device used to measure temperatures accurately and consists of two dissimilar metals joined so that a voltage is generated between to the contacts of the two metals as the temperature changes. Transducer An electrical device that provides a usable output (4-20 mA, 0-5 vDC, etc.) in response to a measured property (pressure, temperature, etc.). Transformer An electrical device that transfers energy from one circuit to another by electromagnetic induction. Transient Voltage Surge Suppressor An electrical device that prevents temporary over-voltages of short duration (typically associated with lightning strikes and ground faults on an ungrounded system) from damaging other electrical equipment. Transmitter An electrical device that sends the digital representation of a real measured value (e.g., pressure, temperature), to the BCM in the control panel for analysis and display. TVSS See Transient Voltage Surge Suppressor. Twisted Pair Wire Paired cables allow balanced signal transmission, which results in signals with low noise. Due to the improved noise immunity of twisted pairs, data speeds are usually higher than those of multi-conductor cables. UCM Universal Communications Module. The device that allows outside systems to communicate with the CMC. UL Underwriters Laboratory. Ungrounded System An electrical system, without an intentional connection to ground. Unload This mode is used when starting the compressor before loading, stopping the compressor and during periods of no demand. User Pressure Set Point The local control pressure set point.
VDC Volts Direct Current Voltage Regulator An electrical device that maintains voltage to a predefined level. Wait Timer The delay interval, in seconds, between power up and the ready state. Wire Gage See American Wire Gage. Wonderware One of many SCADA software packages that can be used for air system integration.

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SIERRA CMC TROUBLESHOOTING AND REMOTE COMMUNICATIONS REFERENCE MANUAL

(Part No. 80441801)

INGERSOLL-RAND AIR COMPRESSORS

CMC TECHNICAL REFERENCE MANUAL

CMC TECHNICAL REFERENCE MANUAL

Documentation_______________________________________________________79 System Information ___________________________________________________79

CMC TECHNICAL REFERENCE MANUAL

CMC TECHNICAL REFERENCE MANUAL

General - CMC Panel

CMC TECHNICAL REFERENCE MANUAL

Protection and Monitoring

Analog Input (AI) Fail

CMC TECHNICAL REFERENCE MANUAL

CMC TECHNICAL REFERENCE MANUAL

Alarm and Trip Settings

CMC TECHNICAL REFERENCE MANUAL

Figure 1: Troubleshooting Tree

CMC TECHNICAL REFERENCE MANUAL

b) The value read by the CMC is incorrect. i)

CMC TECHNICAL REFERENCE MANUAL

Input/Output (I/O) System

CMC TECHNICAL REFERENCE MANUAL

Checking for Power to the Temperature Transmitter

mA COM V RTD Temperature transmitter

CMC TECHNICAL REFERENCE MANUAL

Thermometer RTD 32 DEGF

CMC TECHNICAL REFERENCE MANUAL

CMC TECHNICAL REFERENCE MANUAL

CMC TECHNICAL REFERENCE MANUAL

CMC TECHNICAL REFERENCE MANUAL

Checking proper operation of the BCM and wiring

Input/Output (I/O) System

CMC TECHNICAL REFERENCE MANUAL

CMC TECHNICAL REFERENCE MANUAL

CMC TECHNICAL REFERENCE MANUAL

Temperature, oF 50 75 77 90 150 212 228 239

Temperature vs. Resistance Chart for 10000 ohm at 77 oF Thermistor

CMC TECHNICAL REFERENCE MANUAL

Checking the Thermistor Transmitter

CMC TECHNICAL REFERENCE MANUAL

Checking proper operation of the BCM and wiring

CMC TECHNICAL REFERENCE MANUAL

Erratic OUI readout Incorrect OUI readout

CMC TECHNICAL REFERENCE MANUAL

Checking for Power to the Pressure Transmitter

CMC TECHNICAL REFERENCE MANUAL

CMC TECHNICAL REFERENCE MANUAL

CMC TECHNICAL REFERENCE MANUAL

CMC TECHNICAL REFERENCE MANUAL

CMC TECHNICAL REFERENCE MANUAL

Control Power System (CPS)

J2 +24 VDC pins 11 thru 14 Return pins 7 thru 10 Power Supply

AC2 pin 3 BCM shown cover removed

J10-Power Input (24 VDC)

J9-Current Transformer (0-5 amp)

Analog Input/Output Power

LEGEND: Trace Wire

J3- Analog Output Power 24 VDC (pins 2 & 8)

J1- Analog Input Power 24 VDC (pin 26)

CMC TECHNICAL REFERENCE MANUAL

Troubleshooting Procedure CPS #1 CPS #2 CPS #5

Event Log indicates all digital alarms and trips active

All digital outputs not working

Documentation_____79 System Information _79