Fuji Electric ZKM User manual

Service Manual
INZ-TN5A0506a-E
ZIRCONIA OXYGEN
ANALYZER CONVERTER
transmission specification
(MODBUS)
TYPE: ZKM

i
INZ-TN5A0506-E
CONTENTS
1. COMMUNICATION FUNCTION.................................................................................................. 1
1.1 Outline.....................................................................................................................................................1
2. SPECIFICATIONS .......................................................................................................................... 2
2.1 Communication specifications................................................................................................................2
3. CONNECTION................................................................................................................................ 3
3.1 Setting of jumper pin ..............................................................................................................................3
3.2 Terminal allocation (TM2)......................................................................................................................3
3.3 Connection ..............................................................................................................................................4
4. SETTING OF COMMUNICATION CONDITION........................................................................ 6
4.1 Setting item .............................................................................................................................................6
4.2 Setting operation .....................................................................................................................................6
5. MODBUS COMMUNICATION PROTOCOL............................................................................... 7
5.1 Outline.....................................................................................................................................................7
5.2 Composition of Message.........................................................................................................................8
5.3 Response of Slave Station.......................................................................................................................9
5.4 Function Code.......................................................................................................................................10
5.5 Calculation of Error Check Code (CRC-16).........................................................................................11
5.6 Transmission Control Procedure...........................................................................................................13
6. DETAILS OF MESSAGE ............................................................................................................. 15
6.1 Word data readout [Function code: 03H]...............................................................................................15
6.2 Reading Read-Only Word Data [Function Code: 04H] .........................................................................16
6.3 Writing Word Data (unit of 1word) [function code: 06H] .....................................................................17
6.4 Writing Continuous Word Data [Function code: 10H] ..........................................................................18
7. ADDRESS MAP AND DATA FORMAT .................................................................................... 19
7.1 Data format ...........................................................................................................................................19
7.1.1 Transmission data format............................................................................................................19
7.1.2 Handling of decimal point position and measurement unit ........................................................19
7.1.3 Handling at measurement data over-range..................................................................................19
7.2 Address map..........................................................................................................................................20

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INZ-TN5A0506-E
1. COMMUNICATION FUNCTION
1.1 Outline
•This instrument provides a communication function through RS232-C and RS-485 which allows data
transmit to or receive from the host computer and other devices.
•The communication system is composed of a master and slave relationship.
Up to 31 of slave station (present instrument) can be connected per master station (host computer,
programmable controller, graphic display panel, etc.) through RS485 interface.
One slave station (this instrument) can be connected to one master station.
•Because the master station can communicate with only one slave station at a time, the destination can be
identified by the “Station No.” set for each slave station.
•In order that the master station and slave station can communicate, the format of the transmit/receive data
must coincide. For the PXR, the format of the communication data is determined by the MODBUS
protocol.

2 INZ-TN5A0506-E
2. SPECIFICATIONS
2.1 Communication specifications
(a) RS-232C Interface
Item SPECIFICATIONS
Electrical specification Communication standard: RS-232C
Communication method 2-wire, semi-duplicate
Synchronizing method Start-stop synchronous system
Connection format 1:1
Number connectable units 1 unit
Baud rate 38400 bps
Data length 8 bits
Stop bit 1 bits
Parity None
Data Format
X flow control None
Transmission code HEX value (MODBUS RTU mode)
Error detection CRC-16
Isolation Not isolated against communication part and other parts.
(b) RS-485 interface
Item SPECIFICATIONS
Electrical specification Based on EIA RS-485
Communication method 2-wire, semi-duplicate
Synchronizing method Start-stop synchronous system
Connection format 1:N
Number connectable units 31 units
Communication distance Maximum 500m (total extansion)
Baud rate 38400 bps
Data length 8 bits
Stop bit 1 bits
Parity None
Data Format
X flow control None
Transmission code HEX value (MODBUS RTU mode)
Error detection CRC-16
Isolation Isolation from internal circuit
Functional isolation between signal line and ground

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INZ-TN5A0506-E
3. CONNECTION
WARNING
Do not turn on the power supply until all wiring have been completed to avoid electric shock
and malfunctions.
3.1 Setting of jumper pin
Depending on the kind of communication, switch the jumper pin.
Communication JP1 JP2 JP5
RS 232C 3 - 5
4 - 6
3 - 5
4 - 6 2 - 3
RS 485 1 - 3
2 - 4
1 - 3
2 - 4 1 - 2
3.2 Terminal allocation (TM2)
(a) RS-232C Interface
Terminal number Signal name Pin connection
1 Transmission data (TXD)
2 Receive Data (RXD)
3 Signal ground
123
(b) RS-485 Interface
Terminal number Signal name Pin connection
1 RTxD+
2 RTxD-
3 Singnal ground
123

4 INZ-TN5A0506-E
3.3 Connection
(a) RS-232C Interface
Twisted pair cable
withshield
FG
TXD
RXD
Master Slave (ZKM)
TXD
RXD
SG SG
(b) RS-485 interface
•Please use a shielded twist pair cable.
(Recommended cable: KPEV-SB (made by The Furukawa Electric Co., Ltd.))
•The total extension length of the cable is up to 500 m. One master and up to thirty-one micro
controllers (slaves) can be connected per circuit.
•Both ends of the cable should be terminate with terminating resistors 100Ω(1/2W or more).
•Ground the shielded cable once towards the master side.
  
 




  


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INZ-TN5A0506-E
•SG does not have to be connected, but it can be used as an effective countermeasure against
communication errors due to noise.
•When using the micro controller in an area where the imposed noise level is expected to exceed 500V,
we recommend using a noise filter on the master side as seen in the figure below.
[Noise filter] (Recommended): ZRAC2203-11 (made by TDK Corporation)
RS-485
Noiselter
Master
Mainunit
•If there are problems with EMC during communication, the noise level can be reduced by using a
communication cable with a ferrite core.
Ferrite core (recommended): ZCAT series (made by TDK Corporation)
MSFC series (made by Morimiya Electric Co., Ltd.)

6 INZ-TN5A0506-E
4. SETTING OF COMMUNICATION CONDITION
In order that the master station and instrument (this instrument) can correctly communicate, following settings
are required.
•All communication condition settings of the master station are the same as those of instruments (this
instrument).
•All instruments (this instrument) connected on a line are set to “Station No.” which are different from each
other. (Any “Station No.” is not shared by more than one instrument.)
4.1 Setting item
The parameters to be set are shown in the following table.
Set them by operating keys on the screen.
Item Factory shipment
default Settable range Remarks
Baud rate 38400 bps Fixed (can not be changed)
Data length 8 bits Fixed (can not be changed)
Stop bit 1 bits Fixed (can not be changed)
Parity setting None Fixed (can not be changed)
Set the same communication
condition to the master station
and all slave stations.
Station No. 1 0 to 31
(0: Communication function stops )
Set a different value to each
station.
4.2 Setting operation
Set the station No. on the parameter screen. (Refer to the instruction manual)

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INZ-TN5A0506-E
5. MODBUS COMMUNICATION PROTOCOL
5.1 Outline
The communication system by the MODBUS protocol is that the communication is always started from the
master station and a slave station responds to the received message.
Transmission procedures are as shown below.
1) The master station sends a command message to a slave station.
2) The slave station checks that the station No. in the received message matches with the own station No.
or not.
3) If matched, the slave station executes the command and sends back the response message.
4) If mismatched, the slave station leaves the message and wait for the next command message.
(a) In case when the station No. in the received command message matches with the own slave station No.
Master Slave Command message
Response message Dataon lin
e
Master Slave
(b) In case when the station No. in the received command message matches with the own slave station No.
Master Slave Command message
(No response) Dataon lin
e
Master Slave
The master is connected to the same line by specifying the station No. in the command message. For multiple
slaves, it is possible to communicate individually.

8 INZ-TN5A0506-E
5.2 Composition of Message
Command message and response message consist of 4 fields; Station No., Function code, Data and Error check
code. And these are sent in this order.
Station No. (1 Byte)
Function Code (1 Byte)
Data Part (2 to 133 Bytes)
Error check code (CRC-16) (2 Bytes)
Fig. 5-1 Composition of message
In the following, each field is explained.
(1) Station No.
Station No. is the number specifying a slave station. Only a slave station that corresponds to a value to
which “Station No.” is set on the analyzer maintenance mode display executes a command.
(2) Function code
This is a code to designate the function executed at a slave station.
For details, refer to section 5.4.
(3) Data part
Data are the data required for executing function codes. The composition of the data part is different
depending on the function code. For details, refer to chapter 6.
A register number is assigned to each data in the analyzer. For reading/writing the data by communication,
designate the register number.
Relative address = 





Coil number or register number
of last 4 digits.
– 1
For example, the register number specified by certain function code = in case of 4003
Relative address = (Lower 4 digits of 40003) – 1
= 0002
The message above will be used.
(4) Error check code
This is the code to detect message errors (change in bit) in the signal transmission.
MODBUS protocol (RTU mode) uses CRC16 (Cyclic Redundancy Check).
For CRC calculation method, refer to section 5.5.

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INZ-TN5A0506-E
5.3 Response of Slave Station
(1) Response for normal command
To a relevant message, the slave station creates and sends back a response message which corresponds to
the command message. The composition of message in this case is the same as in Section 5.2.
Contents of the data field depend on the function code. For details, refer to chapter 6.
(2) Response for abnormal command
If there are problems (such as specification of a nonexistent function code) with the contents of the
command message other than transmission error, the slave creates and replies with an error response
message without following the command.
The composition of response message at error detection is as shown in Fig. 5-2 the value used for function
code field is function code of command message plus 80H.
Table 5-1 gives error codes.
Station No. (1 byte)
Function code + 80H(1 byte)
Error code (1 byte)
Error check code (CRC-16) (2 bytes)
Fig. 5-2 Response message at error detection
Table 5-1 Error Code
Error code Contents Explanation
01HIllegal function code Non-actual function code is designated.
Check for the function code.
02HFaulty address for coil or register A relative address of a coil number or resister
number to which the designated function
code can not be used.
03HIllegal data value Because the designation of number is too
much, the area where resister numbers do not
exist is designated.
(3) No response
Under any of the following items, the slave station takes no action of the command message and sends
back no response.
•A station number transmitted in the command message differs from the station number specified to
the slave station.
•An error check code is not matched, or a transmission error (parity error, etc.) is detected.
•The time interval between the composition data of the message becomes longer than the time
corresponding to 24 bits. (Refer to Section 5.6 Transmission Control Procedure)

10 INZ-TN5A0506-E
5.4 Function Code
According to MODBUS protocol, register numbers are assigned by function codes. Each function code acts on
specific register number.
This correspondence is shown in Table 5-2, and the message length by function is shown in Table 5-3.
Table 5-2 Correspondence between function codes and objective address
Function Code Register No.
No. Function Remedy No. Contents
03Hreading (continuance) Holding register 4xxxx Reading/writing Word data
04Hreading (continuance) Input register 3xxxx Reading Word data
06HWriting Holding register 4xxxx Reading/writing Word data
10HWriting (continuance) Holding register 4xxxx Reading/writing Word data
Table 5-3 Function code and message length
[UNIT: byte]
Command
message
Response
message
Function Code Contents Designated
data Mini. Max. Mini. Max.
03HRead word data 64 words 887133
04HRead word (Read only) 64 words 887133
06HWrite word data 1 word 8 8 8 8
10HWrite continuous word data 64 words 11 137 8 8

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INZ-TN5A0506-E
5.5 Calculation of Error Check Code (CRC-16)
CRC-16 is the 2-byte (16-bits) error check code. From the top of the message (station No.) to the end of the
data field are calculated.
The slave calculates the CRC of the received message and ignores the message if this value is not the same as
the received CRC code.
The following shows the calculation procedure for CRC-16.
(a) Store FFFFH into 16 bits register (CRC register)
(b) Subject the 1st byte (8 bits) of transmit message and CRC register contents to an exclusive logical
summation (XOR), and store the result into the CRC register.
(c) Shift the CRC register contents 1 bit to the right. Store 0 at MSB.
(d) If LSB before shifting is 0, do nothing.
If LSB before shifting is 1, subject it and A001H to XOR, and store the result into the CRC register.
(e) Repeat the steps (c) and (d) 8 times (shift by 8 bits).
(f) Execute steps (b) to (e) for the next byte of the transmit message.
Likewise, successively repeat the steps to each byte of the transmit message.
(g) The CRC code that is retained is the value of CRC register that stands when the processing has ended
for latest byte (latest data except error code) of the transmit message.
(h) As error check code of the transmit message, store this CRC value in the order of lower 8 bits and upper
8 bits.
Fig. 5-3 Shows the flow of the CRC-16 calculation system.
01H
06H
00H
05H
03H
E8H
99H
75H
Calculate the date between these
numbers in order, figure out CRC.
In this case, CRC=75 99H
Attach the error check code to
message upon interchanging the
upper CRC and lower orders.
Transmit message (ex.)

12 INZ-TN5A0506-E
Fig. 5-4 Flow of CRC-16 calculation
Start
Set FFFFH(hexadecimal number) in CR.
Set 1 to I
Exclusive-OR (XOR) runs on each character
of J (one byte) for CR and the specified
message, and sets that result to CR.
Set 1 to J
Add 1 to J
Bit at right end
of CR is 1?
After CR has been adjusted one
bit to the right, A001H and XOR
run and set that result to CR.
Shift CR to right by 1 bit.
Calculation (8 times)
is finished?
J>8
Add 1 to I
Calculation of all
characters is completed?
I>All characters
Close
YES
YES
YES
NO
NO
NO
*Explanation of variables
CR : CRC error check data (2 bytes)
I : Digits of calculation characters in
command message
J : Check on the number of times of
CR calculation
Calculation is executed in the order of
command message station No., function
code and data.
CR calculation result shall be added to
the last command message in the order
of LOW byte and HIGH byte.

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INZ-TN5A0506-E
5.6 Transmission Control Procedure
(1) Transmission procedure of master station
The master station must proceed to a communication upon conforming to the following items.
(1-1) The command message, must be sent after an empty space of at least 48 bit time.
(1-2) Interval between bytes of 1 command message is smaller than 24 bits time.
(1-3) After sending a command message, for less than 24 bit time the master will enter receiving
standby.
(1-4) After receiving the response message, the next command message must be sent after at least 48
bit time. [Same as in (1-1)]
(1-5) For safety reasons, create a framework where the master checks the response message, and if
there is no response or an error occurs, retry at least three times.
Note) The definitions written above are for the minimum required value. For safety reasons, we
recommend creating a master side program that keeps margins two to three times as large.
Concretely, it is advised to arrange the program for 38400 bps with 5ms or more for vacant statues
(1-1), and within 1ms for byte interval (1-2) and changeover from sending to receiving (1-3).

14 INZ-TN5A0506-E
(2) Explanation
1) Frame detection
The status on the line of the communication system is one of the 2 below.
(a) Vacant status (no data on line)
(b) Communication status (data is existing)
The units connected on the circuit start in receiving state and monitor the circuit. When a blank state
appears on the circuit for at least 24 bit time, the unit detects the end of the previous frame, and within
the next 24 bit time, enters receiving standby. When data appears on the circuit, the unit begins
receiving data, and once another blank state of at least 24 bit time is detected, that frame is ended. In
other words, the data on the circuit from the first time that a 24 bit time blank state appears to the
second time one appears is loaded as one frame (a bundle of data).
Therefore, one frame (command message) must be sent while following the rules below.
(1-1) The command message must be sent after an empty space of at least 48 bit time.
(1-2) Interval between bytes of 1 command message is smaller than 24 bits time.
2) Response of this instrument
After the PUM detects the frame (detects blank states at least 24 bit times long), that frame is used to
send a command message. If the command message is destined to the own station, a response message
is returned. Its processing time is 1 to 30 ms (The time may change depending on the contents of the
command message.)
Therefore, one frame (command message) must be sent while following the rules below.
(1-3) After sending a command message, for less than 24 bit time the master will enter receiving
standby.
POL1 POL2
POL1 POL2POL1 Response data
POL1 Response data
Space time of longer than 25 ms
is needed.
(5ms or more is recommendable)
1 to 30msec
Control
Station →Main unit
Control
Station ←Main unit
Data on line

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INZ-TN5A0506-E
6. DETAILS OF MESSAGE
6.1 Word data readout [Function code: 03H]
Function code Max. number of words
to read in one message Relative address {Register No. Contents
03H64 words 0000 to 0081 40001 to 40082 Setting data
(1) Composition of Message
Command message composition (byte) Response message composition (byte)
Station No. Station No.
Function code Function code
Upper Readout byte number Readout word number × 2
Readout start number
(Relative address) Lower Upper
Upper
Contents of the first
word data Lower
Readout Word number Lower 


1 to 60 Upper
Upper
Contents of the next
word data Lower
CRC data Lower
Upper
Contents of the last
word data Lower
Upper
CRC data Lower
Arrangement of read-out word data
MSB LSB
Upper byte of contents of the first word data
Lower byte of contents of the first word data
Upper byte of contents of the next word data
Lower byte of contents of the next word data
Upper byte of contents of the last word data
Lower byte of contents of the last word data
(2) Explanation of Function
Word data of continuous word numbers from the read-out start No. can be read. Read-out word data are
transmitted from the slave station in the order of upper and lower bytes.
~~
~ ~

16 INZ-TN5A0506-E
6.2 Reading Read-Only Word Data [Function Code: 04H]
Function code Max. number of words
to read in one message Relative address {Register No. Contents
0000 to 0081 30001 to 30079 Internal data
1000 to 1049 31001 to 31044 Error history data
2000 to 2049 32001 to 32044 Alarm history data
04H64 words
3000 to 3049 33001 to 33044 Operation history data
(1) Composition of message
Command message composition (byte) Response message composition (byte)
Station No. Station No.
Function code Function code
Upper Readout byte number Readout word number × 2
Readout start number
(Relative address) Lower Upper
Upper
Contents of the first
word data Lower
Readout Word number Lower 


1 to 60 Upper
Upper
Contents of the next
word data Lower
CRC data Lower
Upper
Contents of the last
word data Lower
Upper
CRC data Lower
Arrangement of read-out word data
MSB LSB
Upper byte of contents of the first word data
Lower byte of contents of the first word data
Upper byte of contents of the next word data
Lower byte of contents of the next word data
Upper byte of contents of the last word data
Lower byte of contents of the last word data
(2) Description of functions
Word data of continuous word numbers from the read-out start No. can be read. Read-out word data are
transmitted from the slave station in the order of upper and lower bytes.
~~
~ ~

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INZ-TN5A0506-E
6.3 Writing Word Data (unit of 1word) [function code: 06H]
Function code Max. number of words
to read in one message Relative address {Register No. Contents
06H1 words 0000 to 0081 40001 to 40082 Setting data
(1) Composition of message
Command message composition (byte) Response message composition (byte)
Station No. Station No.
Function code Function code
Upper Upper
Write in designation
No. (Relative address) Lower
Write in designation
No. (Relative address) Lower
Upper Upper
Write in word data Lower Write in word data Lower
Upper Upper
CRC data Lower CRC data Lower
(2) Description of function
Designated word data is written in write-in designate No. The master sends the data to be written from
the upper number of bytes to the lower number.

18 INZ-TN5A0506-E
6.4 Writing Continuous Word Data [Function code: 10H]
Function code Max. number of words
to read in one message Relative address {Register No. Contents
10H64 words 0000 to 0081 40001 to 40082 Setting data
(1) Composition of message
Command message composition (byte) Response message composition (byte)
Station No. Station No.
Function code Function code
Upper Upper
Write in start No.
(Relative address) Lower
Write in start number
(Relative address ) Lower
Upper Upper
Write in word
number Lower 


1 to 60 Write in word
number Lower
Upper
Write in byte number 


Write in word number × 2 CRC data Lower
Upper
First write in word
data Lower
Upper
Next write in word
data Lower
Upper
Last write in word
data Lower
Upper
CRC data Lower
Arrangement of write in word data
MSB LSB
Upper byte of contents of the first word data
Lower byte of contents of the first word data
Upper byte of contents of the next word data
Lower byte of contents of the next word data
Upper byte of contents of the last word data
Lower byte of contents of the last word data
(2) Description of functions
Word data of continuous word number is written from write-in start address. The master sends the data
to be written from the upper number of bytes to the lower number.
~ ~
~ ~