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APARIAN A-MBR User Manual

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Modbus Router /
Modbus Router 485
User Manual
A-MBR / A-MBR-485
Document No. D106-009
12/2017
Revision 1.15

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  • Page 1 Modbus Router / Modbus Router 485 User Manual A-MBR / A-MBR-485 Document No. D106-009 12/2017 Revision 1.15...

  • Page 2: Table Of Contents

    CONTENTS Preface ..........................5 1.1. Introduction to the Modbus Router ................5 1.2. Features ........................5 1.3. Architecture ......................... 7 1.4. Additional Information ....................9 1.5. Support ........................9 Installation ........................10 2.1. Module Layout ......................10 2.2. Module Mounting ..................... 13 2.3.
  • Page 3 1.1.2. Output Assembly....................52 4.3. Unscheduled Messaging ................... 53 4.3.1. Example ......................57 Diagnostics ........................59 5.1. LEDs ........................... 59 5.2. Module Status Monitoring in Slate ................60 5.3. Modbus Diagnostics ....................65 5.4. Modbus Packet Capture .................... 66 5.5. Module Event Log......................
  • Page 4 Revision History Revision Date Comment 24 June 2015 Initial document 24 July 2015 Indication of serial data and stop bits supported 25 August 2015 Add UL Listed mark 7 September 2015 Added documentation for the RS485 version 28 September 2015 Added section for Base Address selection 30 September 2015 Add support for EtherNet/IP retry statistics and configuration...

  • Page 5: Preface

    1.1. INTRODUCTION TO THE MODBUS ROUTER This manual describes the installation, operation, and diagnostics of the Aparian Modbus Router. The Modbus Router provides intelligent data routing between EtherNet/IP and Modbus (serial Modbus-RTU or Ethernet Modbus-TCP). NOTE: The Modbus Router 485 can communicate on serial RS485 whilst the Modbus Router can communicate on serial RS232.
  • Page 6 The Modbus Router transfers messages received from a Logix Logix (Msg) Message Instruction. (Modbus Master) Table 1.1. – Modes of Operation Router is configured using the Aparian Slate application. This program can be Modbus downloaded from www.aparian.com free of charge. Slate offers various configuration methods, including a controller tag browser.

  • Page 7: Architecture

    Preface 1.3. ARCHITECTURE The figure below provides an example of the typical network setup in reactive mode, where the Modbus Router acts as a Modbus slave device. Figure 1.2. - Example of a typical network setup in reactive mode By converting and redirecting serial Modbus messages from legacy devices to EtherNet/IP, the module provides an interface for data exchange to Allen-Bradley ControlLogix and CompactLogix platforms.
  • Page 8 Preface Figure 1.3. - Example of a typical network setup in scheduled/unscheduled mode Systems that rely on a central ControlLogix communicating to a number of remote Modbus devices, (e.g. Electrical Protection Units or Remote Terminal Units), may find the Modbus Router useful when operating in Scheduled Tag Mode as shown in the figure above.

  • Page 9: Additional Information

    ADDITIONAL INFORMATION The following documents contain additional information that can assist the user with the module installation and operation. Resource Link Slate Installation http://www.aparian.com/software/slate Modbus Router User Manual Modbus Router Datasheet http://www.aparian.com/products/modbusrouter Example Code & UDTs www.cisco.com/c/en/us/td/docs/video/cds/cde/cde205_220_420/installation/guide/ Ethernet wiring standard cde205_220_420_hig/Connectors.html...

  • Page 10: Installation

    Installation 2. INSTALLATION 2.1. MODULE LAYOUT The module has three ports at the bottom of the enclosure as shown in the figure below. The ports are used for Ethernet, RS232 or RS485 serial, and power. The power port uses a three- way connector which is used for the DC power supply positive and negative (or ground) voltage as well as the earth connection.
  • Page 11 Installation Figure 2.2 – Modbus Router (RS485) side and bottom view The module provides three diagnostic LEDs as shown in the front view figure below. These LEDs are used to provide information regarding the module system operation, the Ethernet interface, and the auxiliary communication interface (RS232 or RS485). Figure 2.3.
  • Page 12 Installation DIP Switch Description DIP Switch 1 Used to force the module into “Safe Mode”. When in “Safe Mode” the module will not load the application firmware and will wait for new firmware to be downloaded. This should only be used in the rare occasion when a firmware update was interrupted at a critical stage.

  • Page 13: Module Mounting

    Installation 2.2. MODULE MOUNTING The module provides a DIN rail clip to mount onto a 35mm DIN rail. Figure 2.4 - DIN rail specification The DIN rail clip is mounted on the bottom of the module at the back as shown in the figure below.

  • Page 14: Power

    RS232 PORT NOTE: The RS232 port is only applicable with the RS232 version of the Modbus Router (catalog A-MBR). The four-way RS232 connector is used to connect the transmit (TX), receive (RX), and GND conductors for serial communication. The shield terminal can be used for shielded cable in high noise environments.

  • Page 15: Rs485 Port

    2.5. RS485 PORT NOTE: The RS485 port is only applicable with the RS485 version of the Modbus Router (catalog A-MBR-485). Figure 2.8 – RS485 connector The four-way RS485 connector is used to connect the positive (+) and negative (-) communication conductors for serial communication. The shield terminal can be used for shielded cable in high noise environments.

  • Page 16: Ethernet Port

    Installation 2.7. ETHERNET PORT The Ethernet connector should be wired according to industry standards. Refer to the additional information section in this document for further details. Document No. D106-009 Page 16 of 76 Revision 1.15...

  • Page 17: Setup

    Setup 3. SETUP 3.1. INSTALL CONFIGURATION SOFTWARE All the network setup and configuration of the module is achieved by means of the Aparian Slate device configuration environment. This software can be downloaded from http://www.aparian.com/software/slate. Figure 3.1. - Aparian Slate Environment 3.2.
  • Page 18 Setup Figure 3.3. - DHCP Server NOTE: If the DHCP requests are not displayed in the DHCP Server it may be due to the local PC’s firewall. During installation the necessary firewall rules are automatically created for the Windows firewall. Another possibility is that another DHCP Server is operational on the network and it has assigned the IP address.
  • Page 19 Setup The successful assignment of the IP address by the device is indicated by the green background of the associated row. Figure 3.5. - Successful IP address assignment It is possible to force the module back into DHCP mode by powering up the device with DIP switch 2 set to the On position.
  • Page 20 Setup Figure 3.7. - Selecting the Target Browser The Target Browser automatically scans the Ethernet network for EtherNet/IP devices. Figure 3.8. - Target Browser Right-clicking on a device, reveals the context menu, including the Port Configuration option. Figure 3.9. - Selecting Port Configuration Document No.
  • Page 21 Setup All the relevant Ethernet port configuration parameters can be modified using the Port Configuration window. Figure 3.10. - Port Configuration Alternatively, these parameters can be modified using Rockwell Automation’s RSLinx software. Document No. D106-009 Page 21 of 76 Revision 1.15...

  • Page 22: Creating A New Project

    Setup 3.3. CREATING A NEW PROJECT Before the user can configure the module, a new Slate project must be created. Under the File menu, select New. Figure 3.11. - Creating a new project A Slate project will be created, showing the Project Explorer tree view. To save the project use the Save option under the File menu.
  • Page 23 Setup Figure 3.13 – Selecting a new Modbus Router The device will appear in the Project Explorer tree as shown below, and its configuration window opened. The device configuration window can be reopened by either double clicking the module in the Project Explorer tree or right-clicking the module and selecting Configuration.

  • Page 24: Modbus Parameters

    MODBUS PARAMETERS The Modbus parameters will be configured by Slate. Refer to the additional information section for documentation and installation links for Aparian Slate. The Modbus parameter configuration consists of a general configuration as well as a serial configuration. When downloading this configuration into the module it will be saved in non-volatile memory that persists when the module is powered down.
  • Page 25 Setup Logix ControlLogix or CompactLogix controllers. MicroLogix/SLC MicroLogix or SLC controllers. ENIP Retry Limit The amount of EtherNet/IP retries the module will make once no response was received from the Logix Controller. ENIP TimeOut The time in milliseconds after which a retry is sent. Once the first retry is sent the next retry will be sent after the same amount of time.
  • Page 26 Setup Multi-Slave When this option is selected the user can select multiple nodes for the mapping items in the Reactive Tag Map. This will allow the Modbus Router to emulate multiple Modbus Node Addresses. Node Address The Modbus node address of the Modbus Router. BAUD Rate The BAUD rate will configure at what speed the data is send across the RS232 serial network.

  • Page 27: Message Routing

    Setup 3.5. MESSAGE ROUTING The module can be configured to route Modbus data in one of three modes:  Reactive Tag mode Schedule Tag mode  Unscheduled mode  3.5.1. EACTIVE The Reactive Tag routing mode allows mapping of virtual Modbus registers to Logix tags across multiple controllers.
  • Page 28 Setup 3.5.1.1. L OGIX ONTROLLER The Logix controller paths can either be entered manually or the user can browse to them by clicking the Browse button. The Target Browser will open and automatically scan for all available EtherNet/IP devices. If the Ethernet/IP module is a bridge module, it can be expanded by right-clicking on the module and selecting the Scan option.
  • Page 29 Setup The second part of the Reactive Tag mode is to configure the link between a Modbus function and register range to a Logix tag. This will allow the Modbus message initiator to effectively write to, or read from, a Logix tag using traditional Modbus functions. Figure 3.20 –...
  • Page 30 Setup NOTE: When doing a single/multiple coil/discrete write to a Logix Bool array datatype the remaining bits of the 32-bit aligned Bool array will be overwritten. Next the range of Modbus data to be accessed must be specified. This is achieved by selecting a Register Start and Element Count.
  • Page 31 Setup NOTE: It is the user’s responsibility to ensure that the Logix tag data type and size matches that of the Modbus message requests. Failing to do this can cause unexpected results and communication faults. Figure 3.22 - Reactive Tag mode configuration in Slate (example route 1) Figure 3.23 - Reactive Tag mode configuration in Slate (example route 2) Document No.
  • Page 32 Setup 3.5.1.2. M /SLC C ICRO OGIX ONTROLLER The MicroLogix/SLC controller paths can either be entered manually or the user can browse to them by clicking the Browse button. The Target Browser will open and automatically scan for all available EtherNet/IP devices. Figure 3.24 - Target Browser selection The required MicroLogix/SLC controller can then be chosen by selecting it and clicking the Ok button, or by double-clicking on the controller module.
  • Page 33 Setup Modbus read and write functions involve the transfer of either Booleans or integers (16 bit). A part or combination of integers may represent other types. For this reason, the Modbus Router allows the mapping of integer based functions to the following data types when using the MicroLogix/SLC controller: ...

  • Page 34: Scheduled Tag Mode

    Setup Figure 3.26 – File Selection for MicroLogix/SLC Controller Type The message routing executes in the exact same way as the Logix Controller type in section 3.5.1.1. 3.5.2. CHEDULED The Scheduled Tag routing mode transfers data between Modbus devices and Logix controllers.
  • Page 35 Setup Figure 3.27 - Scheduled Tag configuration The Schedule Tag mode is configured in three steps. First the user must create a Target Name (CIP path to the destination Logix controller) which will be used to link the Modbus function and register range to the destination Logix tag.
  • Page 36 Setup Figure 3.29 - Target Browser selection The required Logix controller can then be chosen by selecting it and clicking the Ok button, or by double-clicking on the controller module. A maximum number of 3 controller mapping entries can be added. The second part of the Scheduled Tag mode setup is to configure the scan intervals.
  • Page 37 Setup Figure 3.30 – Scheduled Tag Mapping The Modbus Function is used to determine the actual Modbus command to be sent to the device, as described in the table below: Selected Function Modbus Data Type Single / Multiple Modbus Function Read Coil Boolean Both...
  • Page 38 Setup Modbus read and write functions involve the transfer of either Booleans or integers (16 bit). A part or combination of integers may represent other types. For this reason, the Modbus Router allows the mapping of integer based functions to the following Logix data types: ...

  • Page 39: Unscheduled Mode

    Setup Figure 3.31 – Tag Browser tag selection 3.5.3. NSCHEDULED There is no additional configuration required when using the Unscheduled Mode. The configuration required for the Modbus message is contained within the Message Block data, configured in Logix. Refer to the operation section for more information. Document No.

  • Page 40: Module Download

    Setup 3.6. MODULE DOWNLOAD Once the Modbus configuration has been completed, it must be downloaded to the module. Before downloading the Connection Path of the module should be set. This path will automatically default to the IP address of the module, as set in the module configuration. It can however be modified, if the Modbus Router is not on a local network.
  • Page 41 Setup Figure 3.34 - Selecting Download Once complete, the user will be notified that the download was successful. Figure 3.35 - Successful download During the download process the module’s time will be compared to that of the PC’s time. Should the difference be greater than 30 seconds, the user will be prompted to set the module time to that of the PC time.

  • Page 42: Rslogix 5000 Configuration

    Installation tool will be invoked to complete the registration. Alternatively, the EDS file can be downloaded from the product web page at http://www.aparian.com/products/modbusrouter and registered manually using the EDS Hardware Installation Tool shortcut under the Tools menu in Studio 5000.
  • Page 43 Figure 3.39 – Adding a module The module selection dialog will open. To find the module more easily, use the Vendor filter to select only the Aparian modules as shown in the figure below. Document No. D106-009 Page 43 of 76...
  • Page 44 Setup Figure 3.40 – Selecting the module Locate and select the Modbus Router or Modbus Router 485 module, and select the Create option. The module configuration dialog will open, where the user must specify the Name and IP address as a minimum to complete the instantiation. Figure 3.41 –...
  • Page 45 Setup Figure 3.42 – Logix IO tree The Module Defined Data Types will automatically be created during the instantiation process. These data types provide meaningful structures to the module data. An excerpt of the Input Image is shown in the following figure. Figure 3.43 –...

  • Page 46: Rslogix 5000 Configuration (Pre-Version 20)

    Setup 3.7.2. 5000 C OGIX ONFIGURATION ERSION 3.7.2.1. A I/O C ODULE TO ONFIGURATION The module can operate in both a Logix “owned” and standalone mode. When the module operates in a Logix “owned” mode the Modbus Router will need to be added to the RSLogix 5000 IO tree.
  • Page 47 Setup Figure 3.45 - General module properties in RSLogix 5000 NOTE: The user will need to enter the exact connection parameters before the module will establish a class 1 connection with the Logix controller. Next the user needs to add the connection requested packet interval (RPI). This is the rate at which the input and output assemblies are exchanged.
  • Page 48 Setup Figure 3.47 – RSLogix 5000 I/O module tree 3.7.2.2. I MPORTING S AND APPING OUTINES To simplify the mapping of the input image, an RSLogix 5000 Routine Partial Import (L5X) file is provided. This file can be imported by right-clicking on the required Program and selecting the Import Routine option.
  • Page 49 Setup The import will create the following:  The required UDTs (user defined data types)  Two controller tags representing the Input and Output assemblies.  A routine mapping the ModbusRouter module to the aforementioned tags.  An example Unscheduled Message instruction with the associated Tags The user may need to change the routine to map to the correct Modbus Router module instance name, and make sure that the mapping routine is called by the Program’s Main Routine.

  • Page 50: Operation

    Operation 4. OPERATION 4.1. MESSAGE ROUTING When the module has been correctly setup the Modbus message initiator will send a read/write to a certain Modbus group and variation which will then be routed to a Logix tag. The messages sent by the initiator must be completed with the correct data for successful operation.

  • Page 51: Input Assembly

    Operation Figure 4.1. - Input assembly UDT structure 1.1.1. I NPUT SSEMBLY The following parameters are used in the input assembly of the module. Parameter Datatype Description Instance STRING This parameter is the instance name of the module that was configured under the general Modbus configuration in Slate.

  • Page 52: Output Assembly

    Operation Status.ConfigurationValid BOOL Set if a valid configuration is executing in the module. Status.RoutingInhibited BOOL Set when the module’s routing function has been inhibited. Routing can be inhibited by setting a bit in the output assembly of the module. Status.Reserved1…3 BOOL Reserved.

  • Page 53: Unscheduled Messaging

    Logix Controller type in unscheduled mode. To simplify the configuration of the required message a number of UDTs have been preconfigured, and are available on the Aparian ModbusRouter webpage (see the further information section). The message instruction should be setup as follows: Figure 4.3.
  • Page 54 Operation Figure 4.4. - Message Configuration Parameter Description Message Type CIP Generic Service Type Custom Service Code 6A (Hex) - Unscheduled Modbus Pass-through Class 40E (Hex) Instance Attribute Source Element The request tag instance. Must follow the structure of the AparianModbusMessageRequest UDT. Source Length Destination Element The response tag instance.
  • Page 55 Operation Figure 4.5. - Messsage Configuration - Communication The Path must be configured to that of the Modbus Router. If the Modbus Router has been added in the I/O tree, then the Browse option can be used to select the path. Alternatively, enter the CIP path in the format : 1,X,2,IP , where 1 represents the backplane port,...
  • Page 56 Operation Parameter Description Destination Address The Modbus node address of the destination device. Function The Modbus function code. (See the table below for common function codes.) Port The Modbus Router supports two ports to interface to a Modbus device: 0 – Serial Port (Modbus-RTU). 1 - Ethernet Port (Modbus-TCP).

  • Page 57: Example

    Operation Write Single Coil Write Single Register Read Exception Status Diagnostic Get Comm Event Counter Get Comm Event Log Write Multiple Coils Write Multiple Registers Report Server ID Read File Record Write File Record Mask Write Register Read/Write Multiple Registers Read FIFO Queue Table 4.6 - Common Modbus Functions The following table shows common Status / Exception codes.
  • Page 58 Operation The standard ModbusMessageRequest structure is populated as shown in the figure below. Figure 4.8. – Modbus Message Request Example Document No. D106-009 Page 58 of 76 Revision 1.15...

  • Page 59: Diagnostics

    Diagnostics 5. DIAGNOSTICS 5.1. LEDS The module provides three LEDs for diagnostics purposes as shown in the front view figure below. A description of each LED is given in the table below. Figure 5.5.1 - Modbus Router front view Description The module’s Ok LED will provide information regarding the system-level operation of the module.

  • Page 60: Module Status Monitoring In Slate

    The statistics can be accessed in full by Slate or using the web server in the module. To view the module’s status in the Aparian-Slate environment, the module must be online. If the module is not already Online (following a recent configuration download), then right-click on the module and select the Go Online option.
  • Page 61 Diagnostics Figure 5.5.4. - Status monitoring - General The General tab displays the following general parameters and can also be used to set the module time to the PC time: Parameter Description Mode Indicates the current operating mode : Reactive Tag, or Scheduled Tag, or Unscheduled.
  • Page 62 Diagnostics Processor Scan The amount of time (microseconds) taken by the module’s processor in the last scan. Ethernet Cable Length Indicates the estimated length of the Ethernet cable attached to the module. (Accuracy of 5m) DIP Switch Position The status of the DIP switches when the module booted. Note that this status will not change if the DIP switches are altered when the module is running.
  • Page 63 Diagnostics Data Alignment Errors The Modbus request and associated mapped item is not byte aligned with the destination Logix tag. Illegal Function The number of times the Modbus device responded with an Illegal Function exception. Illegal Data Address The number of times the Modbus device responded with an Illegal Data Address exception.
  • Page 64 Diagnostics Statistic Description Current Connections The number of current open class 3 connections. Connection Failures The number of failed attempts at establishing a class 3 connections with a Logix controller. Tag Not Exist Errors The number of tag read and tag write transactions that failed due to the destination tag not existing.

  • Page 65: Modbus Diagnostics

    Diagnostics Statistic Description File Read Count The number of file read transactions executed by the Modbus Router module. File Write Count The number of file write transactions executed by the Modbus Router module. Error Count The number of status errors received from the SLC/MicroLogix by the Modbus Router.

  • Page 66: Modbus Packet Capture

    Diagnostics between the Master and Slave. The following sub-functions are supported for Modbus Diagnostics: Sub-function Description code Return Query Data Restart Communication Return Diagnostic Register Clear Counters and Diagnostics Register Return Bus Message Count Return Bus Communication Error Count Return Bus Exception Error Count Return Server Message Count Return Server No Response Count Return Server NAK Count...
  • Page 67 Diagnostics Figure 5.9. - Selecting Modbus Packet Capture The Modbus Packet Capture window will open and automatically start capturing all Modbus packets. Figure 5.10. – Modbus packet capture To display the captured Modbus packets, the capture process must first be stopped, by pressing the Stop button.
  • Page 68 Diagnostics Figure 5.11. – Modbus Packet Capture complete The captured Modbus packets are tabulated as follows: Statistic Description Index The packet index, incremented for each packet sent or received. Time The elapsed time since the module powered up. Status The status of the packet. Received packets are checked for valid Modbus constructs and valid checksums.

  • Page 69: Module Event Log

    Diagnostics Figure 5.12. - Selecting the Modbus Packet Capture Viewer 5.5. MODULE EVENT LOG The Modbus Router module logs various diagnostic records to an internal event log. These logs are stored in non-volatile memory and can be displayed using Slate or via the web interface.

  • Page 70: Web Server

    Diagnostics The log can also be stored to a file for future analysis, by selecting the Save button in the tool menu. To view previously saved files, use the Event Log Viewer option under the tools menu. 5.6. WEB SERVER The Modbus Router provides a web server allowing a user without Slate or RSLogix 5000 to view various diagnostics of the module.

  • Page 71: Technical Specifications

    Technical Specifications 6. TECHNICAL SPECIFICATIONS 6.1. DIMENSIONS Below are the enclosure dimensions as well as the required DIN rail dimensions. All dimensions are in millimetres. Figure 6.6.1 – Modbus Router enclosure dimensions Figure 6.6.2 - Required DIN dimensions Document No. D106-009 Page 71 of 76 Revision 1.15...

  • Page 72: Electrical

    Technical Specifications 6.2. ELECTRICAL Specification Rating Power requirements Input: 10 – 28V DC, (70 mA @ 24 VDC) Power consumption 1.7 W Connector 3-way terminal Conductors 24 – 18 AWG Enclosure rating IP20, NEMA/UL Open Type Temperature -20 – 70 °C Earth connection Yes, terminal based Emissions...

  • Page 73: Serial Port (Rs232)

    Technical Specifications 6.4. SERIAL PORT (RS232) Specification Rating RS232 Connector 4-way terminal RS232 Conductor 24 – 18 AWG RS232 Isolation voltage 2.5 kV BAUD 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200 Parity None, Even, Odd Data bits Stop bits Table 6.3 –...

  • Page 74: Certifications

    Technical Specifications Protocols Modbus RTU, Modbus TCP Table 6.5 – Modbus specification 6.7. CERTIFICATIONS Certification Mark CE Mark UL Mark File: E494895 CLASS 1, DIV 2, GROUPS A, B, C, D ODVA Conformance *MBR - F/W 1.009 *MBR485 - F/W 1.004 RoHS2 Compliant Table 6.6 –...

  • Page 75: Index

    Index INDEX Logix platform, 5, 7, 8 Logix tag, 24, 27, 29, 31, 32, 35, 36, 50, 51, 52, 54 Logix Tag Map, 27, 30 assembly instance, 46 Mapping Mode, 24 checksum, 59 MODBUS, 1, 5, 6, 7, 8, 9, 10, 11, 14, 15, 22, 23, 24, 25, class 1, 46, 47, 50 26, 27, 29, 30, 31, 32, 33, 34, 35, 36, 38, 39, 40, 46, CompactLogix, 5, 7...
  • Page 76 Index transmit (TX), 10, 14, 15 User Defined Types (UDTs), 47 UDTs, 9, 47, 48, 49, 50, 53 web server, 60, 69 Unscheduled, 6, 24, 27, 39, 49, 51, 53, 54, 55, 56, 61, 64 Document No. D106-009 Page 76 of 76 Revision 1.15...

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