P.V.G.s College of Engineering and Technology, Pune.

A PROJECT ON

MODBUS BASED DISTRIBUTED CONTROL SYSTEM

BY PUJARI SUJAY TOPHKHANE SAURABH KUMTHEKAR AVADHOOT

Under Guidance of Prof. Mrs. M. P. Atre

Technical Assistance W.A.K.E.

Project Category INHOUSE PROJECT

CERTIFICATE

This is to certify that following students have satisfactorily completed their project titled MODBUS BASED DISTRIBUTED CONTROL SYSTEM, towards the fulfillment of Bachelors Degree in Electronics & Telecommunication Engineering.

Kumthekar Avadhoot D. Pujari Sujay G. Tophkhane Saurabh S.

B-3073034 B-3073046 B-3073086

Prof. Mrs. M. P. Atre. Project Guide

Prof. N. P. Deshpande Head, Dept of E & TC

ACKNOWLEDGEMENT
Firstly, we would like to express our sincere thanks to our Internal Guide Prof. Mrs. M.P. Atre whose guidance, supervision, patience and support has been instrumental in the successful completion of this project.

We would also like to thank our Project Coordinator, Prof. Mr. P. G. Shete, our Head of the department, Prof. Mr. N. P. Deshpande and Prof. R. G. Kaduskar for supporting the project and extending their help and co-operation.

We would like to thank W.A.K.E. foundation and our classmates for their timely help and unconditional support. Without them, lot of our problems would have been left unsolved. Last but not the least; we would like to extend our appreciation to the nonteaching staff who are always eager to help us by providing us with the necessary equipments.

Pujari Sujay Girish. Kumthekar Avadhoot Dattatraya Tophkhane Saurabh Sanjay.

TABLE OF CONTENT:

SR.NO

TITLE

PAGE NO.

I II 1. 2. 3. 4. 5. 6. 7.

LIST OF FIGURES LIST OF TABLES SYNOPSIS LITERATURE SURVEY INTRODUCTION SYSTEM SPECIFICATION BLOCK DIAGRAM BLOCKWISE DESIGN DESIGN APPROACH 1)SERVER 2)RS485 IMPLEMENTATION 3)SCADA SYSTEM

6 7 8 9 10 12 14 15 16

8. 9. 10. 11. 1 2. 13.

HARDWARE DESIGN SOFTWARE DESIGN APPLICATION TESTING FUTURE SCOPE BIBLIOGRAPHY

4

19 29 48 50 54
55

14. 15. 16.

APPENDIX CIRCUIT DIAGRAM DATA SHEETS

56 62 69

I.
Figure5.1 Figure 6.1 to 6.4

LIST OF FIGURES

Block diagram DCS..14

Internal Block diagram of all modules...15 DCS system flow chart.16 power supply design.20 5

Figure7.1 Figure8.1

Figure8.2 Figure8.3 Figure8.4 Figure9.1 Figure9.2 Figure9.3 To 9.8

RS485 biasing circuit....24 Driver circuit for Buzzer....25 Signal conditioning circuit.27 Network layer.....30 Modbus Transaction diagram..36 ..37 Flowcharts of various functions ..to....42

Figure9.9 Figure10.1 Figure14.1 Figure14.2 Figure14.3 Figure14.4 Figure14.5 Figure15.1 Figure15.2 Figure15.3 Figure15.4

RTU frame..45 Application block diag...48 Modbus protocol &ISO model comparison....56 Modbus Frame...58 Address rule...58 4 wire Topology for RS485..59 CRC calculations...59 Module C.63 Module B.64 Module A.65 Module D.66

II. LIST OF TABLES

Table9.1 Table9.2 Table9.3 Table9.4 Table9.5 Table14.1 System supported functions30 Exception code..31 Address allotment of Module A...43 Address allotment of Module B...43 Address allotment of Module C...44 Primary table...57 6

Table15.1

Components & Bill...60,61

1. SYNOPSIS
Modbus based Distributed control System (DCS) Domain: Industrial process automation. Hardware Platform: 8-bit microcontroller. Programming Language: Embedded C. Application layer protocol: Modbus Protocol (A de-facto Industrial Application layer protocol),SPI. Physical Layer Interface: RS-232, RS-485. Parameter monitoring SCADA 7

System will continuously monitor the temperature and stores the value in its internal memory. On receiving a Modbus command from the PC based software / Control system with specified formatted protocol will send the read value as a Modbus response. A temperature can be set through the PC based software which can send indication over Modbus at some other remote place. A 24V to 5V DC/DC Converter is used to power up the system . According to alarm Trigger Pt. Setting Buzzer & Leds will indicate. Control over all 3 modules from module D or Master is over MODBUS-RS485.

2. LITERATURE SURVEY
To get basic knowledge about Modbus protocol, we referred following Web resources: 1. www.MODICON.com 2. www.wikipedia.com 3. www.google.com.

After getting used to with protocol, we started from Physical layer which tells about topology, for that we referred Application Note[AN002] from www.modicon.com,[Mazi] and [JanS] . 8

For RS232 www.maxim.com.

we

referred:

Application

note

[AN723],[AN2020]

from

For RS485 we referred: Application note[AN1063],[AN736],AN[723] from www.maxim.com. & [SLLA272B] from www.TI.com Power supply design concepts were found from [Boye]. Moving further towards upper layers, we decided to implement system modules using Atmega32 controller, which is 8-bit controller from AVR family. To study this we referred [DhanG]. Software tools used: IDE: AVRSTUDIO4, Compiler: WINAVR, Downloader: FreeIsp, Ref: Manual: doc2510, doc1019. While working on UART again [JanS] was useful. To Implement Application layer with device profile Ref: Application Note [AN001], [AN003]

3. INTRODUCTION
Name of project: Our project is named as Modus based Distributed Control System. It is basically a model which just demonstrates system Need of project: In industries there are certain processes where human intervention is not possible due to harsh environmental conditions and criticality of application, but at the same time physical parameter like temperature, pressure, air flow etc. have to be monitored and controlled. Remote monitoring and controlling is must in such cases, which is RTU . Our system is a RS-232/ RS485 based temperature transmitter can read the surrounding temperature, send this data over Modbus protocol to the PC based software or a PLC control system which controls it. A distributed control system (DCS) in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers 9

DCS is a very broad term used in a variety of industries, to monitor and control distributed equipment. Why MODBUS? 1)It is openly published and royalty-free 2)Relatively easy industrial network to deploy 3)It moves raw bits or words without placing many restrictions on vendors

Basic idea & approach: we are going to develop distributed control system Which consist of 4 modules->master taking service from 3 slaves (Servers). Master-> pc : module D. Slaves->Module A: Temp module Module-D Is PC based Modbus Master running SCADA - supervisory control and data acquisition systems Module-A 10 Module B: Generic module Module C: Alarm & process status indicator . They all will communicate using Modbus protocol over RS-485.

System will continuously monitor the temperature and stores the value in its internal memory. At particular trigger point of temperature set by master alarm module will come in picture. Module-B Generic module is universal sensing device. User also has to feed data read in the form of 0-5v and conversion factor. Module-C This module consists of two parts 1) To indicate exceeding of trigger point temperature . 2) For the purpose of controlling part 3LEDs are provided to show different works or functions.

4. SYSTEM SPECIFICATION
Power I/P: 230 v ac, 50Hz

1)Module A: Intelligent Temperature Sensor Module Temp Range: Display: Communication port: Resolution : 0 to 100C 16x2 Character Display Modbus over RS485 (TWI). 0.1C

2)Module B: Generic Analog I/P Module Variable I/p: Display: 0 to 5v simulating any physical quantity 16x2 Character Display

Communication port: Modbus over RS485 (TWI). 11

Resolution:

10bit

3)Module C:Alarm & process status indicator Communication port: Modbus over RS485 (TWI) Two Alarm Signals: Visuals: 3 LEDs . Audio: Buzzer . 4) RS232-Rs485 Converter 2 communication port: RS232/RS485 RS 485-2 wire configuration Calculated Termination Resistance 5) Module D: PC Based mini SCADA System VB/Turbo c Based Front End s/w Communication: Modbus Master over RS 232 Data Logging Facility Alarm Trigger Pt Setting Monitoring Parameter 6) UART: Baud Rate Supported (bps):4800, 9600, 19.2k, 38.4k, 57.6k, and 115.2k Data Bits: 7, 8 Parity: N, 0, E Stop bits: 1(for E), 2 12

Flow Control: None

Domain: Hardware Platform: Programming Language: Application layer protocol: Physical Layer Interface: Data Link Layer Interface: Parameter monitoring Software using (PC based Mini SCADA system) :

Industrial process automation. 8-bit microcontroller.(ATMega32) Embedded C. Modbus Protocol RS-232, RS-485. UART

VB 6.0 / VC++.

5. BLOCK DIAGRAM

LT1
RS PC (SCADA SYSTEM) 232 485 RS Generic Device

D: MODBUS Master

B: MODBUS Slave
Temperatur e Module Alarm and process status

A: MODBUS Slav 13

C: MODBUS Slave LT2 Fig 5.1

6. BLOCKWISE DESIGN
1) MODULE A: Temp Module

A
TTL to 485

TTL

Controller

ADC

TEMPRATURE SENSOR

Fig 6.1 2) MODULE B : Generic device A TTL

Controller

ADC

0 to 5V analog I/p

TTL to 485

B Fig 6.2 3) MODULE C: Alarm and Process status indicator A

TTL to 485

TTL

Controller 14

Leds & Buzzer

B Fig 6.3 4) MODULE D: PC based mini SCADA system A

PC

Serial port RS232

RS232 232

TTL

TTL to 485

To TTL
Fig 6.4

7. DESIGN APPROACH

15

Fig 7.1 DCS system Flowchart ->

SLAVE BOOTING PROCESS

MASTER BOOTING

POLL FOR SLAVE DEVICES

SET CONDITION FOR ALARM

START MONITORING THE PROCESS

YES SET ALARM OR LEDS

CHECK FOR CONDITIO

NO

System is broadly divided in 3 parts 1) SERVER 2) RS485 implementation 3) SCADA system 1) SERVER 16

Hardware approach : These are modules A,B&C In which common requirement s are 8-bit microcontroller->AVR ATMEGA32 selected Power supply ->230v to 9v conversion.

For the purpose of testing of various interfaces like 1) Ttl-Rs232 2) Downloading section 3) Display unit 4) ADC interface & many more A unique Development board built around ATmega32 Is required. Module a) 1) Sensor selection according to resolution and range->LM35 2) Signal condition circuit3) LCD interface Module b) To make it user friendly, Menu driven->tactile switches & LCD Device protection circuitry Module c) Hooter and led indicator. Logical approach: 17

Module b) module will show 2 modes on display 1) Program mode User can select parameter to be sensed & its convergent factor 2) Run mode Run mode is common for all modules or server It just means server waiting for command from client & eager to respond. 2) RS-485 implementation 1) For level conversion needed for slaves -> RS485 TTl Transceivers (for slaves) 2) For level conversion needed for master -> RS232-RS485 -> A) RS232 to TTL and TTl to RS485 transceiver B) RS232 to RS485 transceiver 3) Termination resistance selection-> 3) SCADA system 1) Modbus Master- slave driver implementation Programming language-visual basic 2) Graphics User Interface

18

8. HARDWARE DESIGN

1)

POWER SUPPLY DESIGN

19

1N 4007 2 1

U 2 L M 7 8 0 5 C /T O IN G N D O U T

Vin=24V
DC

Vout=5V
0 .1 u F

600uF

0 .3 3 u F

regulated

Fig 8.1 As shown in above diagram; Bridge rectifier: I/P=24V. It is commonly used circuit for large amount of DC power. At one time two diodes conduct simultaneously. We are using 1N4007 diodes. Voltage drop=0.7*2=1.4V So O/P of bridge rectifier is 24-1.4=22.6V.

Filters: A circuit that removes ripples from a rectifier output without affecting DC voltage is known as filter. We are going to use capacitor filter. We will assume ripple factor as 5%. We know; Ripple factor= r=Vr(rms)/Vdc. =Idc/4*31/2*f*C*Vdc =1/4*31/2*f*C*RL Substituting values; 20

0.05 =1/ 4*31/2*f*C*RL Now we have for our modules; Idc=150mA RL=5/150mA=33.33ohm So we have 0.05= 1/ 4*31/2*f*C*33.33 C = 1732uF. C=2200uF (standard). IC7805: From datasheet we have; 1. Wide input range: 7-35V 2. Max current capacity:1A 3.Output voltage : 5V regulated..

Then i/p of IC 7805 ; Vdc=22.6v (I/P range for ic 7-35V)

Capacitors Cin and Co are used at input and output side of IC. Need of capacitor: 1. Capacitor Cin filters out effects of stray inductance of input wire. 2. Output capacitor is generally not used but it improves the transient of Regulator.

Power dissipation consideration: We know from datasheet IC has max. PD=2W. We know Power dissipation =(Vin-Vout)*Io. 21

We have Io=150mA and Vin to 7805=22.6V For max.2W PD we need Vin-Vout=2W/0.5 =4V But we have Vin-Vout =17.6V So in our case PD will be PD=17.6*150mA PD =2.64W Since we have more PD we NEED heat sink We are going to use general 25x50 mm Heat Sink which dissipates power up to 3 watts.

2) Controller selection (ATMega32) 8-bit Microcontroller Advanced RISC Architecture Large amount of In-System Self-programmable Flash program memory 22

At least 1K Bytes EEPROM Inbuilt 8-channel 10-bit ADC Programmable Serial USART Baud Rate achievable 115Kbps @ Fosc=3.6864MHz With 0% error Sophisticated IDE, Software tools like compiler, library

Free downloading circuit and software Availability of prototype board

23

mV between A and B data line.

Fig 8.2 As we know that using modbus we can connect up to 32 devises. so RS485 can have at max 32 nodes. In our case we are going to use 3 slaves and 1 master. So we have 4 RS485 Nodes. Each RS 485 node has load impedance of 12K. so for such 4 nodes in parallel give load of 3k. 24

Minimum requirement of voltage between terminals A and B=200mV. So to maintain this voltage the bias current required to flow through load is given by Bias current=200mV/(120||3K||120) Bias current =3.4mA Now to calculate bias resistance value we have; 3.4mA=5V/(2R+(120||3K||120)) 2R+59=5V/3.4mA 2R+59=1470 2R=1411 R=705 ohm. Value used=700 ohm 4) Transistor driver circuit for buzzer
5 V

4 0 0 o h m L S 1 1 2 B U Z Z E R

R 2 5V 4 7 K o h m 2

1 B C 5 4 7 3

Fig 8.3 For 5V supply, Since buzzer draws about 1.5 mA we will consider Ic as 10mA.. So 25

Ic =10mA. From datasheet; 1. Applying KVL to C-E; Vcc=Ic*R1+Vce 5=10mA*R1+1 R1=400 ohm. For Ib we know; Ib=Ic/Hfe(min). From datasheet of BC547 we have; Hfe(min)=110. So, Ib=10mA/110 Ib =90.90uA. Vce=1V.

2. Applying KVL to B-E, we have VIN=Ib*R2+Vbe 5=Ib*R2+0.7 4.3=Ib*R2 4.3=90.90uA*R2 R2=4.3/90.90uA R2=47.3047Kohm. So we have R1=400ohm and R2=47.3047kohm.

5)SIGNAL CONDITIONING

26

Fig 8.4 For non inverting amplifier ; Gain: 1+Rf/Ri. Required gain: Vo/Vin: =5/1.5 =3.333. We will use Ri=1K then we have 3.33=1+Rf/1K Rf=2.33K.. We will use 10K pot as Rf. So we have Ri=1K and Rf=10K(variable) Now for offset nulling technique as shown in figure We are going to use LM358 so Vcc=5V and from datasheet of that opamp we got value of input offset voltage as 7mV(max). 27

V=Vcc=5V Vios=(Rc/Rb)V 7mV= (Rc/Rb)5 Rb=1400Rc Choose Rc as 20 ohm.. then we have Rc=20ohm Rb=1400*20 =28Kohm Take Rmax=Rb/10 so Rmax=2800 As we know Rmax=Ra/4 Ra/4=2800 Ra=11.2Kohm(this is variable one) We can adjust this variable Ra till the output reaches to zero..

28

9. SOFTWARE DESIGN

Device Profile Modbus Application layer UART RS-485 29

Network layer

Fig 9.1

As per our system consider, We support following Functins: Primary Table Discrete Input Coil Object type Single bit Single bit Access Type Read Only Function Reference Supported 1x 0x2 0x1 0x5 0x4 0x3 0x6 0x10

Read/Write 0x

Input Register Holding Register

16 bit word 16 bit word

Read Only 3x Read/Write 4x

Table 9.1

Exception Codes Code Name 30 Meaning

01

ILLEGAL FUNCTION

02

ILLEGAL DATA ADDRESS

The function code received in the query is not an allowable action for the slave. If a Poll Program Complete command was issued, this code indicates that no program function preceded it. The data address received in the query is not an allowable address for the slave. A value contained in the query data field is not an allowable value for the slave. An unrecoverable error occurred while the slave was attempting to perform the requested action. The slave has accepted the request and is processing it, but a long duration of time will be required to do so. This response is returned to prevent a timeout error from occurring in the master. The master can next issue a Poll Program Complete message to determine if processing is completed.

03

ILLEGAL DATA VALUE

04

SLAVE DEVICE FAILURE

05

ACKNOWLEDGE

Table 9.2
Algorithms Main for Module A : 1. Start 31

2. Initialize all variable. 3. Initialize all Ports. 4. Initialize ADC. 5. Initialize UART for Baud rate 9600,no Parity,1 Start and 1 Stop bit. 6. Init Timer0;
7. Enable USART_RXC Interrupt.

8. Set Global Interrupt Enable pin high. 9. Loop 10. Check sampling rate and log data into eeprom using internal ADC 11. Go to step 9

Main for Module B: 1. Start 2. Initialize all variable. 3. Initialize all Ports. 4. Initialize ADC.
5. Initialize UART for Baud rate 9600, no Parity, 1 Start and 1

Stop bit. 6. Init Timer0;

7. Enable USART_RXC Interrupt.

8. Set Global Interrupt Enable pin high. 9. Loop 10. Check sampling rate and log data into eeprom using internal ADC 32

11. Go to step 9 Main for Module C 1. Start 2. Initialize all variable. 3. Initialize all Ports. 4. Initialize UART for Baud rate 9600,no Parity,1 Start and 1 Stop bit. 5. Init Timer0;
6. Enable USART_RXC Interrupt.

7. Set Global Interrupt Enable pin high. 8. Loop 9. Go to step 9

ISR-RECIEVED COMPLETE 1. clear interrupt enable 2. disable USTART complete 3. initialize timer for 10usec 4. enable timer interrupt 5. received byte[count] = received byte 6. count = count +1 7. set delay count for 3.5msec 8. set interrupt enable

ISR-Transmission COMPLETE 1. Clear interrupt enable 33

2. If Current= Byte to send then go to step 3 Else transmit que[current++];go ot step 4; 3. Disable transmit complete interrupt TIMER 0 interrupt enable 4. Set interrupt enable. ISR-Timer0 1. Clear interrupt enable 2. if delay counter ON go to step 3 3. if delay count2=0 then delay counter OFF else delay count 2=delay count2 - 1 4. if delay count!=0, then delay count= delay count - 1 Go to step 7 5. if count=0, then no of bytes received = count else go to step 7 6. if first received byte [0] = slave id a) Call updateQue() b) Enable USART transmission complete interrupt c) Transmit Que[0] d) Current = 1 7. Preset counter. 8. Send interrupts enable flag. UpdateQue 1. Current = 0 2. Que(0) = slave id 3. If login, then go to step4 else go to step 6 34

4. Check if exception 5. if exception a) Que(1) = 80Hex + received byte [1] b) Que(2) = Exception code c) byte to send=3 d) return 6. if password wrong a) send exception 4 b) return 7. Que(1) = received byte [1] 8. serve functions 9. return

STATE DIAGRAMs UpdateQue() Whenever Responding to any query wile updating Queue of Response frame it may be Exception or Normal Response.

35

Figure 9.2 : Modbus Transaction diagram.

Function 1

ENTR

MB Server receives mb_req_pdu

36

NO

Function code

Starting ExceptionCode=04 Address & Quantity of Registers Server ExceptionCode=02 0x0001quantity of Registers Sends mb_rsp YES Request MB Exit processing ExceptionCode=01 NO YES YES MB Server Sends mb_exception_rsp OK ExceptionCode=03 NO 0x007D

NO

YES

ReadDiscreteOutp

Figure 9.3 : Read Coil state diagram

Function 2

ENTR

MB Server receives mb_req_pdu

37
NO
Function code

Starting ExceptionCode=04 Address & Quantity of Registers ExceptionCode=01 Server ExceptionCode=02 0x0001quantity of Registers Sends mb_rsp YES Request MB Exit processing NO YES YES MB Server Sends mb_exception_rsp OK ExceptionCode=03 NO 0x007D

YES NO

Read Discrete Inputs

Figure 9.4 : Read Discrete Inputs state diagram

Function 3

ENTR

MB Server receives mb_req_pdu

NO
ExceptionCode=01

Function code 38

YES

0x0001quantity of Registers Starting ExceptionCode=04 Address & Quantity of Registers Server ExceptionCode=02 0x007D Request MB Exit processingSends mb_rsp YES NO YES YES MB Server Sends mb_exception_rsp OK ExceptionCode=03 NO

NO

ReadMultipleRegister

Figure 9.5 : Read Holding Register state diagram

Function 4

39

Fig 9.6

Function 5

40

YES

ENTR

MB Server receives mb_req_pdu

NO
ExceptionCode=01

Function code

YES

NO
0x0001quantity of Registers 0x007D

ExceptionCode=03

YES

NO
ExceptionCode=02

Starting Address & Quantity of Registers OK

YES
Request processing

NO
ExceptionCode=01

WriteSingleOutput

YES

MB Server Sends mb_rsp

MB Server Sends mb_exception_rsp

Exit

Figure 9.7 : Write Single Output state diagram

Function 6

41

ENTR

MB Server receives mb_req_pdu

NO
ExceptionCode=01

Function code

YES

NO
ExceptionCode=03

0x0001quantity of Registers 0x007D

YES
Starting Address & Quantity of Registers OK

NO
ExceptionCode=02

YES
Request processing

NO
ExceptionCode=04

WriteSingleRegister

YES
MB Server Sends mb_rsp

MB Server Sends mb_exception_rsp

Exit

Figure 9.8 : Write Single Register state diagram

Data address allotment Module A : s.n. Task 1 Enter passwod Data model Holding Register 42 Access R/W Start address 400020 Ending address 400024

2 Login Status 3 Logoff 4 Current data 5 Sample rate Hour Minute Seconds Retrieve logged 6 data 7 No. valid loggs 8 Access nth log 9 Choose unit Module B : s.n. 1 2 3 4 Task Enter passwod Login Status Logoff Current data

Input Coil Output coil Input Register Holding Register

R/O R/W R/O R/W

100001 000010 300001 400100 400100 400101 400102 000001 300002 301000 400002 400102

Output coil Input Register Input Register Holding Register Table 9.3

R/W R/O R/O R/w

304999

5 Sample rate Hour Minute Seconds Retrieve logged 6 data 7 No. valid loggs 8 Access nth log 9 Read unit 10 Scaling Factor

Data model Holding Register Input Coil Output coil Input Register Holding Register

Access R/W R/O R/W R/O R/W

Start address 410020 110001 010010 310001 410100 410100 410101 410102 010001 310002 311000 313002 312000

Ending address 410024

410102

Output coil Input Register Input Register Input Register Input Register Table 9.4

R/W R/O R/O R/O R/O

314999

Module C: s.n. Task Data model Holding Register Input Coil Start Access address R/W R/O 43 420020 120001 Ending address 40024

1 Enter passwod 2 Login Status

3 Logoff 4 Buzzer 5 LEDs

Output coil R/W Output coil R/W Output coil R/W Table 9.5

20001 20020 20100

20102

Calculations: Timer 0 interrupt for 100uS: TCCR0 = 0x02; Resultant clock source after multiplier = Fcrystal/8. Fclk = 3.6864MHz/8=460.8KHz. TCNT0 = 210; Resultant time=(256-TCNT0)/Fclk =46/460.8K =100uSec. UART: UBRR Settings for 3.6864MHz crystal. Ref:Page166 Table 69 AtMega32 datasheet ,for 0% error up to 230.4K baud rate.

Delay count for Time Out: MODBUS Message RTU Framing A MODBUS message is placed by the transmitting device into a frame that has a known beginning and ending point. This allows devices that receive a new frame to begin at the start of the message, and to know when the message is completed. Partial messages must be detected and errors must be set as a result.

44

In RTU mode, message frames are separated by a silent interval of at least 3.5 character times. In the following sections, this time interval is called t3,5.

Fig 9.9

Specifically, about 9600 baud rate. In 9600 Baud rate each bit takes 1/9600 seconds to transmit. For whole frame (Normal)= 1 start+1 stop+8 data bits=10bits=> So require 10*1/9600 seconds. Which is time taken for transmitting 1 char so for 3.5 char time taken will be=10*3.5/9600=3.5mSec. For 3.5 msec with help of 100usec Interrupt popping out . So ,we require 3.5m/100u=35 as Delay count.

SCADA Design: 45

SCADA usually starts with login process and after that continuously monitor for expected information. While designing there are many free SCADAs available to use with MODBUS like-> Modscan32, SimplyModbus6.3.6 (Master) & very useful Docklight. First of all we tried with Docklight

Wrong Id, wrong password, password . At the last, Logoff.

46

Expected GUI ( Font end) under VB2008

Algorithm followed->
1. Select device from user. Generate slave ID accordingly. 2. Check login status, if login then continuously monitor for current reading. 3. Else ask for password. Unless right one is not entered.

In Back End, it will monitor for trigger point and take accordingly action.

10. APPLICATIONS
47

process control Factory floor automation Manufacturing process Industrial process automation Industrial process automation: Press Forging

Press forging Forging is one of the oldest known metalworking processes In modern times, industrial forging is done either with presses or with hammers powered by compressed air, electricity, hydraulics or steam. These hammers are large, having reciprocating weights in the thousands of pounds. Press forging is an operation characterized by the process of deformation which consists of a lot of heating and cooling. During the process, the material is slowly condensed into a shape by increasing pressure. There are two dies; one stationary and one pushed towards the other, which compresses the part. Press forging is variation of drop-hammer forging. Unlike drop-hammer forging, press forges work slowly by applying continuous pressure or force. The main advantage of press forging, as compared to drop-hammer forging, is its ability to deform the complete work piece MODBUS
Pc based SCADA 2 3 2 4 8 5 Generic Device Temperatur e Module Pressure sensor & Conditioning

Over RS485

Vin (condition: 0v<Vin<5v)

Conversion Factor
Process status

GND

Fig 10.1 Press Forging Beryllium Copper Billet: http://www.freedomalloysusa.com/index.html 48

It should be noted that production input billet casting is the beginning point of the manufacturing process which eventually yields the various wrought forms of beryllium copper.

C82500 BeCu Cast Electronic Component

Beryllium copper application: Beryllium copper strip alloys have historically been specified in electronic connector applications in an impressive array of telecommunications, computer, and automotive electronics applications. Beryllium copper rod is utilized to produce certain machined connector designs and beryllium copper casting alloys are specified for intricate miniature investment cast connectors. Undersea fiber optic cable repeater housings and their associated components have been specified in beryllium copper for many years. These beryllium copper housing assemblies (wrought and cast components) must perform flawlessly, for an extended service life measured in decades, in the harsh deep water marine environment of the worlds oceans. Obviously, beryllium coppers special combination of corrosion resistance, high strength, and durability characteristics match the severe operational requirements.

11.TESTING:
Communication 49

*For all serial communication purpose DOCKLIGHT Ver.1.6 s/w used. RS232 Driver Implementation:

Circuit tested on bread board and following PCB is also tested.

Serial Communication with pc 1)First part, RXD & TXD pin shorted, echo of transmitted pattern obtained on PC

2)Second part,100 bytes Sent from Microcontroller and successfully received on PC

50

RS485 Driver Implementation: Circuit Design & PCB: Circuit tested on bread board and following PCB is also tested.

Serial Communication with pc as half duplex Using 2nd PCB in Fig Transmission lines are shorted so as to get back echo on PC.

Serial Communication with pc as full duplex Both PCBs from Fig are used, one for Master side and another for slave side, so that 100 bytes sent from controller received on PC

Driver circuitry for Buzzer Circuit designed resistances values were found out. Implemented on breadboard and tested .verified on multisim .Where buzzer Load impedance found out equal to 5kohm. 51

XMM1 VCC
5V

XMM2

R1
4.3k

R2 R3
47k BC547BP

Q1

390

Temperature sensing: LM35 Using internal ADC of controller temperature is observed on PC. For that LM35 and its signal conditioning circuit is used.

While implementing Timer on timer0 using 2 LEDs connected to 2 pin and implementing toggling algorithem timer of 100usec was verified.

SCADA testing: 52

SCADA tested using Modscan32.exe a freeware SCADA.

12.FUTURE SCOPE
53

We have used 4 wire interface for implementing RS485 . Instead of that we can make use of 2 wire interface. But for that we have to define directional logic which is necessary for that system interface.

There are two types of modes of MODBUS one is RTU and other is ASKII. we have implemented RTU mode. We can implement ASKII mode also.

We have implemented only 6 functions, can be upgraded to fully functional DCS.

For fully fledged system we have to consider effect of Grounding and Isolation

54

13. BIBLOGRAPHY
BOOKS [Boye] Electronic Devices and Circuit Theory. 8th Edition.Robert Boylestad. Prentice Hall India [Mazi] The 8051 Microcontroller and Embedded Systems 2nd Edition, Muhammad Mazidi Pearson Education [JanS] Serial Port Complete Penram International Pvt. Ltd. 2nd Edition, Jan Axleson Programming and customizing the AVR microcontroller-Dhananjay V. Gadre

[Dhan]

APPLICATION NOTES *Modicon.com [AN001] [AN002] [AN003] MODBUS APPLICATION PROTOCOL SPECIFICATION V1.1b MODBUS over Serial LineSpecification and Implementation Guide V1.02 Modicon Modbus Protocol Reference Guide PIMBUS300 Rev. J

*Texas Instruments [SLLA272B] The RS-485 Design Guide February 2008Revised May 2008 *Maxim-IC [AN1063] [AN736] Microcontroller Recognizes Addresses in RS-485 Systems RS-485 (EIA/TIA-485) Differential Data Transmission System Basics

*Analog Devices [AN960] RS-485/RS-422 Circuit Implementation Guide by Hein Marais 55

14. APPENDIX
MODBUS @ The following figure gives a general representation of MODBUS serial communication stack compared to the 7 layers of the OSI model with respect to our system..

Fig 14.1 Application layer Data Encoding MODBUS uses a big-Endean representation for addresses and data items. This means that when a numerical quantity larger than a single byte is transmitted, the most Significant byte is sent first. MODBUS data model MODBUS bases its data model on a series of tables that have distinguishing characteristics.

56

The four primary tables are:

Primary table

Object type

Type of access ReadWrite

Comments

coils

Single bit

This type of data can be alterable by an application program This type of data can be provided by an I/O system

Input registers

16-bit word Read-Only

Holding registers Discrete Input

16-bit word ReadWrite Single bit Read-Only

This type of data can be alterable by an application program This type of data can be provided by an I/O system

Table 14.1

Data link layer: 1) MODBUS frame description The MODBUS protocol defined a simple protocol data unit (PDU) independent of the underlying communication layers. The mapping of MODBUS protocol on specific buses or network can introduce some additional fields on the application data unit (ADU). General MODBUS frame: ADU
ADDITIONAL ADDRESSES FUNCTION CODE

DATA

ERROR CHECK

57

PDU Fig 14.2 The function code 1 byte. (128 255 reserved for exception responses). Max size: RS485 ADU = 256 bytes.PDU for serial line communication = 253 bytes Server address (1 byte) , CRC (2 bytes) 2) MODBUS addressing rules:

Fig 14.3 3) The two serial Transmission Modes Two different serial transmission modes are defined: The RTU mode and the ASCII mode. It defines the bit contents of message fields transmitted serially on the line. It determines how information is packed into the message fields and decoded. The transmission mode (and serial port parameters) must be the same for all devices on a MODBUS Serial Line.

58

General 4 wire topology.

Fig 14.4

59

CRC CALCULATIONS

Fig 14.5

Table 15.1: COMPONENT LIST AND BILL

SR NO 1 2 COMPONENT IC 7805 IC ATMEGA32 ICMAX232 ICMAX485 ICLM35 SPECIFICATIONS 5V regulator 40-pin DIP 16-pin-DIP 8-pin DIP TEMPERATURE 60 QTY 3 3 1 8 1 COST 18 435 25 320 40 (Rs)

SENSOR ICLM324 3 IC base Quad OpAmp 16 pin dip 40 pin dip 8 pin dip 4 Relamet connector 6 pin 2 pin 5 6 7 8 9 Transistor Toggle switch Zener diode Diode Resistors BC547 SPDT 5.1 V 1N4007 1K ohm 0.25watt 10 kohm 0.25watt 15 Kohm 0.25watt 4.7 kohm 0.25 watts 120ohm0.25watts 47Kohm0.25watts 680ohm0.25watts 20ohm0.25watts 402ohm0.25watts 10. 11. Variable Pot Capacitors 10k,1k precesion 1000uF,25V,electrolytic 100 uF,25V,electrolytic 10uF 25V, electrolytic 0.01 uF,22pF ceramic 2200uF, electrolytic 61 2 3 3 8 1 6 1 3 2 16 12 2 1 2 4 1 4 4 1 2 1 1 4 10 2 20 6 12 8 9 12 1 24 2 16 3 0.5 0.25 0.5 1 0.25 1 1 0.25 8 6 2 4 10

12. 13. 14 15 16

Bur strips 2 pin push button LEDs PCB Serial cable

40 pin

3 1

18 2 10

3mm

10

Plug socket DB9

75

17. 18. 19. 20.

DB 9 socket Crystal casing BUZZER

Female 3.6864Mhz

2 1

20 15

3V-24V TOTAL

21

15. CIRCUIT DIAGRAM

62

MODULE C
5V 1 .8 K 400 ohm 1 2 BU ZZER 1 .8 K LS1 b u zzer 1 2 3 4 5 6 7 8 9 10 11 Y 1 C R Y S TA L R x D _ in T x D _ in 12 13 14 15 16 17 C 1 18 19 20 21 U 1 P P P P P P P P B B B B B B B B 0 1 2 3 4 5 6 7 /XC K 0 /T 0 P /T 1 P /IN T 2 /A IN 0 P /O C 0 /A IN 1 P P /S S P /M O S I P /M IS O P /S C K A A A A A A A A 0 1 2 3 4 5 6 7 /A /A /A /A /A /A /A /A D D D D D D D D C C C C C C C C 0 1 2 3 4 5 6 7 40 39 38 37 36 35 34 33 32 31 30 1 .8 K 1 .8 K LED 1 .8 K 1 .8 K LED LED 5V C 3 0 .1 u F LED LED LED

bu zze r

R 2 2 47 Kohm

5V 1 BC 547 3 C 3 0 .1 u F

R ESET VC C G N D XTA L2 XTA L1 P D 0 /R x D P D 1 /T x D P D 2 /IN T 0 P D 3 /IN T 1 P P P P D D D D 4 5 6 7 /O C 1 B /O C 1 A /IC P 1 /O C 2 D IP 4 0

A re f G N D AVC C

22pF C 2

P C 7 /T O S C 2 P C 6 /T O S C 1 P C 5 /TC I PC 4TD O P C 3 /T M S P C 2 /T C K P C 1 /S D A P C 0 /S C L

29 28 27 26 25 24 23 22

5V

C 3 0 .1 u F U 3 T x D _ in 4 2 3 8 D I R E D E +VC C M A X485 JP1 A T x _ in B T x _ in A R x _ in B R x _ in 1 2 3 4 4 H EAD ER R O A B 1 6 7

A T x _ in B T x _ in

22pF

U 4 4 2 3 8 D I R E D E +VC C M A X485 5v C 3 0 .1 u F R O A B 1 6 7

R x D _ in A R x _ in B R x _ in

0-5V

63

Fig 15.1

MODULE B

5V

5V

5V
R 1

C 3 0 .1 u F 8 U 3A 1 LM 358 4 C 1 U 1 1 2 3 4 5V 5 6 7 8 R _ in 9 10 11 Y 1 R x D _ in T x D _ in 12 13 14 15 16 17 1 1 2 2 8 9 0 1 P P P P P P P P B B B B B B B B 0 1 2 3 4 5 6 7 /XC K 0 /T0 P /T1 P /IN T 2 /A IN 0 P /O C 0 /A IN 1 P P /S S P /M O S I P /M IS O P /S C K A A A A A A A A 0 1 2 3 4 5 6 7 /A /A /A /A /A /A /A /A D D D D D D D D C C C C C C C C 0 1 2 3 4 5 6 7 4 3 3 3 3 3 3 3 0 9 8 7 6 5 4 3 2

1 5K ohm R 1 + 3 2 1K ohm R c 2 R a 3 JP1 C 3 0 .0 1 u F A T x _ in B T x _ in A R x _ in B R x _ in 1 2 3 4 A T x _ in B T x _ in R x D _ in A R x _ in B R x _ in 1 5V 3 R b

C 3 0 .1 u F 5V

R _ in 2 1

C 3 C 2 22pF 0 .1 u F

R ESET VC C G N D XTA L2 XTA L1 P D 0 /R x D P D 1 /Tx D P D 2 /IN T 0 P D 3 /IN T 1 P P P P D D D D 4 5 6 7 /O C 1 B /O C 1 A /IC P 1 /O C 2 D IP 4 0

A re f G N D AVC C

32 31 30

C 1

C R Y S TAL 22pF

P C 7 /T O S C 2 P C 6 /T O S C 1 P C 5 /TC I PC 4TD O P C 3 /TM S P C 2 /TC K P C 1 /S D A P C 0 /S C L

2 2 2 2 2 2

9 8 7 6 5 4

5V T x D _ in 4 2 3 8 5V

U 6 D I R E D E

M A X485 R O A B 1 6 7

C 3 0 .1 u F

+VC C

23 22 4 2 3 C 3 0 .1 u F 8

U 6 D I R E D E

M A X485 R O A B 1 6 7

+VC C

64

Fig 15.2

MODULE A
5V 0 .1 u F 2 VO U T U 4 VS+ 1 5V

5V
R 1

C 3 0 .1 u F 8 U 3A 1 LM 358 C 1 4 L M 3 5 /T O + 3 2 1K ohm R c 2 R a 4 3 3 3 3 3 3 3 0 9 8 7 6 5 4 3 R 3 R b 5V 1 JP1 C 3 0 .0 1 u F A T x _ in B T x _ in A R x _ in B R x _ in 1 2 3 4 A T x _ in B T x _ in R x D _ in A R x _ in B R x _ in 3 5V 5V P C 7 /T O S C 2 P C 6 /T O S C 1 P C 5 /TC I PC 4TD O P C 3 /TM S P C 2 /TC K P C 1 /S D A P C 0 /S C L 2 2 2 2 2 2 9 8 7 6 5 4 T x D _ in 4 2 3 8 5V U 6 4 2 3 C 3 0 .1 u F 8 D I R E D E +VC C M A X485 R O A B 1 6 7 U 6 D I R E D E +VC C M A X485 R O A B 1 6 7 C 3 0 .1 u F C 3 0 .1 u F

R _ in 2

U 1 1 2 3 4 5V 5 6 7 8 R _ in 9 10 11 Y 1 R x D _ in T x D _ in 12 13 14 15 16 17 1 1 2 2 8 9 0 1 P P P P P P P P B B B B B B B B 0 1 2 3 4 5 6 7 /XC K 0 /T0 P /T1 P /IN T 2 /A IN 0 P /O C 0 /A IN 1 P P /S S P /M O S I P /M IS O P /S C K A A A A A A A A 0 1 2 3 4 5 6 7 /A /A /A /A /A /A /A /A D D D D D D D D C C C C C C C C 0 1 2 3 4 5 6 7

C 3 C 2 22pF 0 .1 u F

R ESET VC C G N D XTA L2 XTA L1 P D 0 /R x D P D 1 /Tx D P D 2 /IN T 0 P D 3 /IN T 1 P P P P D D D D 4 5 6 7 /O C 1 B /O C 1 A /IC P 1 /O C 2 D IP 4 0

A re f G N D AVC C

32 31 30

C 1

22pF

C R Y S TAL

23 22

65

Fig 15.3

Master: Module D
9 9 5 5 4 4 8 3 3 8 7 2 2 7 6 1 1 R xD TxD _out R xD _out 8 4 2 3 705 U 7 D I R E D E +VC C R 2 M A X 4 8 5 /S O R xD _out TxD 1 0 m ic r o F 1 3 4 5 2 6 13 8 11 10 U 2 R 1 IN R 2 IN T 1 IN T 2 IN C C C C V V + 12+ 2+ U 8 4 2 3 8 5V D I R E D E +VC C M A X 4 8 5 /S O VC C 705 R O A B 1 6 7 TxD A R x _ in 120 R 1 R 2 T1 T2 O O O O U U U U T T T T 12 9 14 7 JP2 R xD TxD _out 5V A R x _ in B R x _ in A T x _ in B T x _ in 1 2 3 4 4 H EAD ER R O A B 1 6 7 A T x _ in 120 B T x _ in 6 VC C 5V

1 0 m ic r o F

705

1 0 m ic r o F

M A X232 1 0 m ic r o F

B R x _ in

RS485 to RS232 conversion on master side(PC)

66

Fig 15.4

67

Layout of basic Prototype board 68

69

16. DATA SHEETS

70