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INGERSOLL-RAND AIR COMPRESSORS SIERRA ® CMC TROUBLESHOOTING AND REMOTE COMMUNICATIONS REFERENCE MANUAL (Part No. 80441801)

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SIERRA CMC TROUBLESHOOTING AND REMOTE COMMUNICATIONS REFERENCE MANUAL(Part No. 80441801)

INGERSOLL-RAND AIR COMPRESSORS

CMC TECHNICAL REFERENCE MANUAL

Copyright NoticeCopyright 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.

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CMC TECHNICAL REFERENCE MANUAL

Table of ContentsReferences ___________________________________________________________2 General - CMC Panel ___________________________________________________3 Protection and Monitoring ______________________________________________4Analog Functions __________________________________________________________ 4 Digital Functions __________________________________________________________ 5

Troubleshooting ______________________________________________________7Troubleshooting Example ___________________________________________________ 8 Input/Output (I/O) System ___________________________________________________ 9 Control Power System (CPS) _______________________________________________ 27 Controller Problems_______________________________________________________ 30

Communication ______________________________________________________32Human 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 ___________________________________________________79Status Codes ____________________________________________________________ 79 Base Control Module (BCM) ________________________________________________ 81 Operator User Interface Module (OUI) ________________________________________ 84 Universal Communication Module (UCM) Optional _____________________________ 88

Glossary _____________________________________________________________1

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ReferencesThe 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

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General - CMC PanelThe 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.

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Protection and MonitoringEach 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 FunctionsAn 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 InputsTwenty-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 OutputsThe Sierra CMC controller does not use any analog outputs.

Analog Input (AI) FailIf 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.

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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 FunctionsA 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 InputsThe 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 OutputsThe 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.

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Alarm and Trip SettingsThese 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.

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TroubleshootingThe 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

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Troubleshooting ExampleThe 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

SERVICETime 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.

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Input/Output (I/O) SystemTemperature 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

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CMC TECHNICAL REFERENCE MANUALTMS #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

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CMC TECHNICAL REFERENCE MANUALChecking 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

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Degrees Fahrenheit versus Ohms value chart for 100 OHM Platinum RTDF 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

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Degrees Celsius versus Ohms value chart for 100 OHM Platinum RTDC -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)

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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

J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23

Pin 25 Pin 1

123 4

100 OHM 5%

Temperature transmitter

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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

J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23

Pin 254-20 mA SURCE OR 2 WIRE SIMULATORmA OUT 2 WIRE OFF

Pin 1XXXXXX MODEL CL-XXXBATTERY CHECK

00.0% - 100%

Input/Output (I/O) SystemTemperature 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

CMC TECHNICAL REFERENCE MANUALA 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

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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.

80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004

18Checking 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.

CMC TECHNICAL REFERENCE MANUALTMS #2a

Temperature, oF 50 75 77 90 150 212 228 2391.92o 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 637.0 491.4 413.95.24% 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

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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.

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CMC TECHNICAL REFERENCE MANUALTMS #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

J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23

Pin 254-20 mA SURCE OR 2 WIRE SIMULATORmA OUT 2 WIRE OFF

Pin 1XXXXXX MODEL CL-XXXBATTERY CHECK

00.0% - 100%

555

LOOP ON

00.0%

100%

DIAL

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CMC TECHNICAL REFERENCE MANUALPressure 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

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CMC TECHNICAL REFERENCE MANUAL

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

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

VAC

INGERSOLL RAND

mA COM V

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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

J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23

Pin 254-20 mA SURCE OR 2 WIRE SIMULATORmA OUT 2 WIRE OFF

Pin 1XXXXXX MODEL CL-XXXBATTERY CHECK

00.0% - 100%

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555

LOOP ON

00.0%

100%

DIAL

24

CMC TECHNICAL REFERENCE MANUAL

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

MXXXXX 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.

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CMC TECHNICAL REFERENCE MANUALDigital 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

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CMC TECHNICAL REFERENCE MANUAL

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 SupplyF1

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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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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CMC TECHNICAL REFERENCE MANUAL

Controller ProblemsDescription: 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.

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CMC TECHNICAL REFERENCE MANUALBCM ProblemsBCM is not controlling CMCS #4 1. Check the CPU power as described in the section titled Control Power System.

31

OUI ProblemsOUI 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 ProblemsAll 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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CMC TECHNICAL REFERENCE MANUAL

CommunicationCustomers 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) SystemsAir 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 RS422/485For 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

CMC TECHNICAL REFERENCE MANUALtells 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 InterfaceIntroductionThe 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.

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CMC TECHNICAL REFERENCE MANUALIn 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

MasterDevice Address Function Code Data Address Data CRC

SlaveDevice Address Function Code Byte Count Data CRC

Serial ModesMODBUS 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 MessagesA 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 AddressThis 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 CodeThe 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

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CMC TECHNICAL REFERENCE MANUALData AddressesAddresses 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.

DataFor 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 CountThe number of bytes contained in the data portion of the message. This is used on both queries (reads) and responses.

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36Cyclical Redundancy Check (CRC)

CMC TECHNICAL REFERENCE MANUAL

This portion of the message is used to prevent incorrect data from being used in the Master or Slave because of communication errors.

Function DetailsFunction 01 - Read Coil StatusThis 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

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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 StatusThis 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.

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CMC TECHNICAL REFERENCE MANUALAbsolute 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

The response from this command is: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.

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CMC TECHNICAL REFERENCE MANUALFunction 03 - Read Holding RegistersReads 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.

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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

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CMC TECHNICAL REFERENCE MANUALSigned 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 RegistersReads 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.

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CMC TECHNICAL REFERENCE MANUALSigned 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.

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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

The response from this command is: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

The response from this command is: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

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CMC TECHNICAL REFERENCE MANUAL

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 76

5

4

3

2

1

0

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 CoilForces 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

CMC TECHNICAL REFERENCE MANUALNOTE 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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44Function 06 - Preset Single Register

CMC TECHNICAL REFERENCE MANUAL

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:

80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004

CMC TECHNICAL REFERENCE MANUALDevice 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 CoilsForces 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

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: 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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CMC TECHNICAL REFERENCE MANUALDevice 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 RegistersPresets 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

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 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.

80441801 Rev. A, Version 3.20 2004 Ingersoll-Rand Company Date of Issue: December 15, 2004

CMC TECHNICAL REFERENCE MANUALAs 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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CMC TECHNICAL REFERENCE MANUALCAUTION

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 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 ResponsesExcept 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

CMC TECHNICAL REFERENCE MANUALFunction Code FieldFor 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 FieldFor 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 MicrocontrollerCode 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 ParametersThe 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 DataThe 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

CMC TECHNICAL REFERENCE MANUAL 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 MeasureThe 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 ParametersConfiguration 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 InterfaceIntroductionCustomers 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 w