APNT#1168 Modbus - Establishing Communications Hints

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1 Application Note #1168: Modbus - Establishing Communications Hints Introduction This document provides supplemental information about configuring Pro-face Device/PLC drivers to communicate with your device. To configure a driver refer to the Pro-face Device Connections Manuals for the software you are using. For supplemental information about cabling your 3rd party device to a Pro-face human machine interface (HMI) display refer to Application note #1167 3rd Party Modbus Serial Cabling Tips. Also, more information about Modbus cabling and communications can be found on the Internet at: Select the Correct Device Driver In most Modbus applications an HMI is a Modbus master and the connected devices are slaves. The Modbus serial protocol allows each slave one master. The GP-Pro EX multi-link feature can be used to add additional HMIs to a Pro-face Modbus serial master. The Modbus TCP protocol allows multiple masters. The number of masters that can connect to a Modbus TCP slave at any one time is limited by the number of simultaneous TCP connections the slave device can handle. GP-Pro EX includes two serial Modbus master drivers. The Schneider Electric SA, MODBUS SIO Master is easy to configure and works in most applications. It allows up to 16 slave devices. The Modbus-IDA General MODBUS SIO Master driver is more adaptable to 3 rd party field devices such as temperature controllers and VF drives. It allows connecting as many as 31 slaves. If the project is GP-Pro/PB3 use the Schneider Modbus RTU 1:n comm. device/plc driver. Whenever possible configure a 3 rd party device for Modbus RTU rather than Modbus ASCII. If a 3 rd party device is Modbus serial ASCII only choose the Modbus IDA serial Master driver in GP-Pro EX. Then, in the Device/PLC Communications Settings, change the default RTU setting to ASCII. GP-Pro EX also includes two Ethernet Modbus TCP master drivers. The Schneider Electric SA, MODBUS TCP Master is easy to configure and works in most applications. The Modbus-IDA General MODBUS TCP Master driver is more adaptable to 3 rd party field devices such as temperature controllers and VF drives. Both drivers allow up to 16 slave devices. If the HMI is a slave and the connected device is the master choose a Modbus Slave driver. GP-Pro EX includes one Modbus slave driver, Schneider Electric SA MODBUS SLAVE. It can be configured for either serial or Ethernet (TCP) connections. In GP-Pro/PB3 select the Modicon Modbus (SLAVE) driver. Additional customized Modbus type drivers are available for GP-Pro EX under other labels that include specific features and modifications for 3 rd party device compatibility such as Control Techniques and Yaskawa. The remainder of this document applies to Modbus master drivers only. Page 1 of 6

2 Configuring and Establishing Communications When connecting a 3 rd party device for the first time we recommend starting with a simple test project. For a test project create a single screen application with a numeric data entry field in the range (%MW if using IEC addressing). Select a register greater than or %MW1. Choose a single register in the 3 rd party device that is 16 bit integer, allows read/write access, is not locked, and permits change via a Modbus connection. Connect o a single slave. For simplicity do not include other memory ranges or bit variables in the initial test project. In the case of Modbus serial set Wait to Send (Send Wait or TX Wait Time) to match the device wait to transmit or wait to send setting. This parameter is also configurable in most 3 rd party devices. If this information is not available for your device begin with the Device/PLC driver default setting. Exception: If the default driver setting is 0 begin with 4msec. (For Modbus TCP the Wait to Send value is typically 0 unless the device is accessed through a TCP to serial bridge) GP-Pro/PB3 only: Uncheck all the registers in the GP Settings/ Extended Settings/ System Area. Select a System Start Address that is a 16 bit read/write register that can be altered in the 3 rd party device. Do not use the System Start Address on any screen. Set the watchdog word address to an unused register like LS100. GP-Pro PB Read Area Size should 0. These settings can be changed in your project as desired later. GP-Pro EX only: Do not enable the System Data Area. It can always be enabled later after communication is established. Do not assume that because the System Data Area is unchecked that the System Start Address is not monitored. Select a readable address that has any constant value in it. Note about devices that support 32 bit words only: If your device has only 32 bit registers configure the test project numeric field as a 32 bit integer. Device addressing is 16 bit word oriented. This means 32 bit words use 2 addresses in the device. (Example: One 32 bit word would occupy and or %MW9 and %MW10.) Use a register greater than or %MW2. GP-Pro EX test project: In Max Query set all words at 2 and all bits at 32 Communication Errors Download the project. If an error appears on the Pro-face unit refer to the software documentation for a description of the error. See section T Troubleshooting in the GP-Pro EX Reference Manual. The suggestions below are additional things to consider: If no data appears on the screen and an error appears: 1> Verify the slave Modbus RTU address (node number) matches the Slave Equipment Address setting in GP-Pro EX. 2> Verify the serial communications settings match the slave equipment. 3> Be sure the slave device is in Run mode and Modbus communications is enabled. 4> Check for cabling or grounding problems. 5> If the serial connection is 2 wire RS485 consider: a. Interchanging the A and B leads. b. In some installations a polarization circuit might be required. Page 2 of 6

3 6> Be sure to have a signal common wire connected. (3 rd wire if RS485 2-wire or RS232, 5 th wire if RS485 4-wire) If the device does not have a signal common connection use signal ground. If neither exists try connecting the common wire to the device frame or earth ground. 7> Serial connections: Set the Wait to Send to 10msec and try again. If still no response try 20 msec. In the case of RS485 2-wire try interchanging the A and B leads again. 8> Remove the numeric entry variable from the test project and download it again. a. If the error no longer appears the memory location that was used for the data display may be write only (i.e. not readable) or read access is not permitted via a Modbus connection. b. If the error still appears the System Start Address may be write only (i.e. not readable) or access is not permitted via a Modbus connection. i. Check if the System Start address in the slave is a 16 bit register and a constant value. ii. Try another system start address. iii. Check the Symbol Editor for symbols without an Address. iv. Verify the Language Change Feature is not enabled. 9> GP-Pro EX only: Many 3 rd party field devices such as drives and sensors require small max query settings. Try changing the individual device settings. a. Change all register max query settings to 2 words. b. Change all the Coil/Discrete Input settings to 16 10> GP-Pro EX only: Change the Single Bit manipulation to Coil/Discrete Input setting. Try again. If it does not solve the issue return it to the default setting. GP-Pro/PB3 only: Some 3 rd party devices that use an earlier implementation of Modbus RTU, especially legacy devices, will only function with the Modicon Corp. Modicon Modbus (MASTER) device/plc driver. If this might be the case Modbus may not be the appropriate driver when upgrading to GP-Pro EX. If some data appears on the screen but a communication error still appears: 1> If an error appears only after trying to write a new value with a data entry keypad the new value may be overwritten by the 3 rd party device, the register is read-only, or write permission is not enabled in the device. Try another memory address. 2> In the case of a serial connection: If an error appears and data is displayed in the numeric field increase the Wait to Send to 10msec. If not successful try 20msec. 3> GP-Pro EX only: Try changing the settings in individual device settings. Change all register max query settings to 2 words.* Change all the Coil/Discrete Input settings to 16. Try again. (in very few cases devices may require a register setting of 1) 3> GP-Pro EX only: If the above changes did not work try the Single Bit manipulation to Coil/Discrete Input setting. Try again. 4> The memory location may be read only or write only or not accessible in the 3 rd party device by the HMI. Try removing the numeric entry box from the project to see if the error disappears. 5> Increase the Wait to Send to 10msec and try again. If not successful try 20msec. 6> Modbus TCP only: Try setting a wait state even when using Modbus TCP. It will slow the requests to the device reducing the communication load on the device and reduce network traffic. Set the Wait to Send to 10msec. If not successful try 20msec. Page 3 of 6

4 If communications are established and incorrect data appears: Some 3 rd party devices use a different bit order or byte order. In the case of 32 bit values such as double word and floating point sometimes the word order is different. 1> Verify that a 16 bit value is located at the expected address in both devices. It is common for the addressing to differ by one word. One way to do this is to place 3 consecutive numeric entry fields on the screen. (Example , , or %M101, %M102, %M103. Monitor the same addresses in the 3 rd party device. Check if the data is written to the correct address when a change is made on the HMI and not the address above or below it. The register addressing may be offset by one word. 2> If the data is written to the correct address, but appears to be the wrong value, try entering a value of 1 from the HMI. If the resulting value in the device is a large number the byte order may be reversed between the units. The byte order can be switched in the HMI using script. 3> If the data is written to the correct address, the next step is to test a 32 bit integer. If the value is incorrect, when using GP-Pro EX, change the Double Word order selection in Device/PLC Individual Device Settings. If the project is GP-Pro/PB3 ideally the words can be swapped in the third party device; if not the words can be swapped using script. If the test program works but the final project has communication errors: Review the sections above that address the problem you encounter. Finally review the Gap and Span section below. Gap and Span For optimum performance most modern protocol drivers read a contiguous block of memory whenever data from memory locations near to one another are requested. The request is recalculated by the driver each time a screen change happens. The blocks of memory requested include all device addresses in ladder and scripts whether they execute or not, the current screen, recipes, data logging, system area, and etc. Three problems can be encountered. 1> The field device cannot handle such a large request. Some PLCs for example can only respond to memory requests of 72 words or less. Solution: In this case we would set the Max Query boundary (Span) to the largest word block size the PLC can handle, 72. Some small field devices can only handle a little as 2 word requests. 2> Read problems can be encountered when memory locations with different access permissions are intermixed in a device. For example if an application needs the driver to read , , , and the driver is set to read the default block size the driver will request Now suppose the address is write only. The 3 rd party device will respond with a read error message. To solve this problem we set the read block size to a lower number in the HMI driver to accommodate the 3 rd party device. In this example the read block size could be set to 5. 3> Read problems can be encountered when requesting very large blocks of memory with small gaps. One problem is when a 32 bit word bridges 2 read blocks. Another problem is read blocks overlapping. To prevent these situations assign addresses in the project to blocks of memory that are no longer than the Span setting without skipping a block of addresses of ½ the Span (gap). In most cases an even number. Page 4 of 6

5 For more information on Pro-face and our full line of HMI, Operator Interface and Industrial PC products please visit our web site at For technical support or call: Pro-face America. Specifications may change without notice. Pro-face is a registered trademark of Digital Corporation. Other brand or product names are the property of their respective owners. Page 5 of 6

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