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

PROJECT

ON

MODBUS BASED DISTRIBUTED CONTROL SYSTEM

BY

PUJARI SUJAY

TOPHKHANE SAURABH

KUMTHEKAR AVADHOOT

Under Guidance of

Prof. Mrs. M. P. Atre

Technical Assistance

W.A.K.E.

Project Category

INHOUSE PROJECT

1
 CERTIFICATE

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

• Kumthekar Avadhoot D. B-3073034

• Pujari Sujay G. B-3073046
• Tophkhane Saurabh S. B-3073086

Prof. Mrs. M. P. Atre. Prof. N. P. Deshpande

Project Guide Head, Dept of E & TC

2
 ACKNOWLEDGEMENT

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

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

We would like to thank ‘W.A.K.E.’ foundation and our classmates for their timely
help and unconditional support. Without them, lot of our problems would have been left
unsolved.

Last but not the least; we would like to extend our appreciation to the non-
teaching staff who are always eager to help us by providing us with the necessary
equipments.

Pujari Sujay Girish.

Kumthekar Avadhoot Dattatraya

Tophkhane Saurabh Sanjay.

3
 TABLE OF CONTENT:

SR.NO TITLE PAGE

NO.
I LIST OF FIGURES 6
II LIST OF TABLES 7
1. SYNOPSIS 8
2. LITERATURE SURVEY 9
3. INTRODUCTION 10
4. SYSTEM SPECIFICATION 12
5. BLOCK DIAGRAM 14
6. BLOCKWISE DESIGN 15
7. DESIGN APPROACH 16

1)SERVER

2)RS485 IMPLEMENTATION

3)SCADA SYSTEM
8. HARDWARE DESIGN 19
9. SOFTWARE DESIGN 29
10. APPLICATION 48
11. TESTING 50

1 2. FUTURE SCOPE 54

13. BIBLIOGRAPHY 55

4
 14. APPENDIX 56

15. CIRCUIT DIAGRAM 62

16. DATA SHEETS 69

I. LIST OF FIGURES
Figure5.1 Block diagram DCS……………………………………………………..14

Figure 6.1

to 6.4 Internal Block diagram of all modules…………………………….…..15

Figure7.1 DCS system flow chart…………………………………………….……16

Figure8.1 power supply design……………………………………………….……20

5
Figure8.2 RS485 biasing circuit……………………………………………….…...24

Figure8.3 Driver circuit for Buzzer……………………………………….………...25

Figure8.4 Signal conditioning circuit……………………………………………….27

Figure9.1 Network layer…………………………………………………….……....30

Figure9.2 Modbus Transaction diagram…………………………….…….………36

Figure9.3 ………….….………37

To 9.8 Flowcharts of various functions ……………………………..to…....42

Figure9.9 RTU frame………………………………………………………………..45

Figure10.1 Application block diag……………………………………………..…….48

Figure14.1 Modbus protocol &ISO model comparison…………………….……...56

Figure14.2 Modbus Frame…………………………………………………………...58

Figure14.3 Address rule……………………………………………………………...58

Figure14.4 4 wire Topology for RS485……………………………………………..59

Figure14.5 CRC calculations………………………………………………………...59

Figure15.1 Module C………………………………………………………………….63

Figure15.2 Module B………………………………………………………………….64

Figure15.3 Module A………………………………………………………………….65

Figure15.4 Module D………………………………………………………………….66

II. LIST OF TABLES

Table9.1 System supported functions……………………………………………30

Table9.2 Exception code…………………………………………………………..31

Table9.3 Address allotment of Module A………………………………………...43

Table9.4 Address allotment of Module B…….…………………………………..43

Table9.5 Address allotment of Module C………………………………………...44

Table14.1 Primary table………………………………………………….…………..57

6
Table15.1 Components & Bill…………………………………………………...60,61

1. SYNOPSIS

Modbus based Distributed control System (DCS)

• Domain: Industrial process automation.

• Hardware Platform: 8-bit microcontroller.
• Programming Language: Embedded C.
• Application layer protocol: Modbus Protocol (A de-facto Industrial Application
layer protocol),SPI.
• Physical Layer Interface: RS-232, RS-485.
• Parameter monitoring SCADA

7
 System will continuously monitor the temperature and stores the value in its internal
memory. On receiving a Modbus command from the PC based software / Control
system with specified formatted protocol will send the read value as a Modbus
response.
A temperature can be set through the PC based software which can send
indication over Modbus at some other remote place.
A 24V to 5V DC/DC Converter is used to power up the system
.
According to alarm Trigger Pt. Setting Buzzer & Led’s will indicate.
Control over all 3 modules from module D or Master is over MODBUS-RS485.

2. LITERATURE SURVEY

To get basic knowledge about “Modbus protocol”, we referred following Web

resources:

1. www.MODICON.com

2. www.wikipedia.com

3. www.google.com.

After getting used to with protocol, we started from Physical layer which tells about
topology, for that we referred Application Note[AN002] from www.modicon.com,[Mazi]
and [JanS] .
8
 For RS232 we referred: Application note [AN723],[AN2020] from
www.maxim.com.

For RS485 we referred: Application note[AN1063],[AN736],AN[723] from

www.maxim.com. & [SLLA272B] from www.TI.com

Power supply design concepts were found from [Boye].

Moving further towards upper layers, we decided to implement system modules

using Atmega32 controller, which is 8-bit controller from AVR family. To study this we
referred [DhanG].

Software tools used:

IDE: AVRSTUDIO4, Compiler: WINAVR, Downloader: FreeIsp,

Ref: Manual: doc2510, doc1019.

While working on UART again [JanS] was useful.

To Implement Application layer with device profile

Ref: Application Note [AN001], [AN003]

3. INTRODUCTION
Name of project:
Our project is named as “Modus based Distributed Control System”. It is
basically a model which just demonstrates system

Need of project:
In industries there are certain processes where human intervention is not
possible due to harsh environmental conditions and criticality of application, but at the
same time physical parameter like temperature, pressure, air flow etc. have to be
monitored and controlled.
Remote monitoring and controlling is must in such cases, which is RTU .

Our system is a RS-232/ RS485 based temperature transmitter can read the
surrounding temperature, send this data over Modbus protocol to the PC based
software or a PLC control system which controls it.
A distributed control system (DCS) in which the controller elements are not
central in location (like the brain) but are distributed throughout the system with each
component sub-system controlled by one or more controllers
9
 DCS is a very broad term used in a variety of industries, to monitor and control
distributed equipment.

Why MODBUS?

1)It is openly published and royalty-free

2)Relatively easy industrial network to deploy

3)It moves raw bits or words without placing many restrictions on vendors

Basic idea & approach:

we are going to develop distributed control system

Which consist of 4 modules->master taking service from 3 slaves (Servers).

Master-> pc : module D.

Slaves->Module A: Temp module

• Module B: Generic module

• Module C: Alarm & process status indicator .
• They all will communicate using Modbus protocol over RS-485.
Module-D

Is PC based Modbus Master running SCADA - supervisory control and data acquisition
systems

Module-A
10
 System will continuously monitor the temperature and stores the value in its
internal memory. At particular trigger point of temperature set by master alarm
module will come in picture.

Module-B

Generic module is universal sensing device. User also has to feed data read in
the form of 0-5v and conversion factor.

Module-C

This module consists of two parts

1) To indicate exceeding of trigger point temperature .

2) For the purpose of controlling part 3LED’s are provided to show different works
or functions.

4. SYSTEM SPECIFICATION

Power I/P: 230 v ac, 50Hz

1)Module A: Intelligent Temperature Sensor Module

Temp Range: 0 to 100˚C

Display: 16x2 Character Display

Communication port: Modbus over RS485 (TWI).

Resolution : 0.1˚C

2)Module B: Generic Analog I/P Module

Variable I/p: 0 to 5v simulating any physical quantity

Display: 16x2 Character Display

Communication port: Modbus over RS485 (TWI).

11
 Resolution: 10bit

3)Module C:Alarm & process status indicator

Communication port: Modbus over RS485 (TWI)

Two Alarm Signals:

Visuals: 3 LEDs .

Audio: Buzzer .

4) RS232-Rs485 Converter

2 communication port: RS232/RS485

RS 485-2 wire configuration

Calculated Termination Resistance

5) Module D: PC Based mini SCADA System

VB/Turbo c Based Front End s/w

Communication: Modbus Master over RS 232

Data Logging Facility

Alarm Trigger Pt Setting

Monitoring Parameter

6) UART:

Baud Rate Supported (bps):4800, 9600, 19.2k, 38.4k, 57.6k, and 115.2k

Data Bits: 7, 8

Parity: N, 0, E

Stop bits: 1(for E), 2

12
 Flow Control: None

• Domain: Industrial process automation.

• Hardware Platform: 8-bit microcontroller.(ATMega32)
• Programming Language: Embedded C.
• Application layer protocol: Modbus Protocol
• Physical Layer Interface: RS-232, RS-485.
• Data Link Layer Interface: UART
• Parameter monitoring Software using
(PC based Mini SCADA system) : VB 6.0 / VC++.

5. BLOCK DIAGRAM

LT1

RS RS
PC
- -
(SCADA
SYSTEM) 232
485 Generic

D: MODBUS Master Device

B: MODBUS Slave
Temperatur
e Module
Alarm
and
process
A: MODBUS Slav status
13
 C: MODBUS Slave

LT2

Fig 5.1

6. BLOCKWISE DESIGN

1) MODULE A: Temp Module

A TTL
Controller ADC TEMPRATURE
485
TTL to

SENSOR
B

Fig 6.1

2) MODULE B : Generic device

TTL
Controller ADC 0 to 5V analog
485
TTL to

I/p
B

Fig 6.2

3) MODULE C: Alarm and Process status indicator

A TTL
Controller Led’s &
485
TTL to

14

Buzzer
B

Fig 6.3

4) MODULE D: PC based mini SCADA system

A
Serial port RS232 232 TTL

485
TTL to
PC
RS232
To TTL B

Fig 6.4

7. DESIGN APPROACH

15
Fig 7.1

DCS system Flowchart -> SLAVE BOOTING

PROCESS

MASTER BOOTING

POLL FOR SLAVE

DEVICES

SET CONDITION
FOR ALARM

START
MONITORING THE
PROCESS

YES NO
SET ALARM CHECK
OR LED’S FOR

CONDITIO

System is broadly divided in 3 parts

1) SERVER

2) RS485 implementation

3) SCADA system

1) SERVER

16
Hardware approach :

These are modules A,B&C

In which common requirement s are

• 8-bit microcontroller->AVR ATMEGA32 selected

• Power supply ->230v to 9v conversion.
For the purpose of testing of various interfaces like

1) Ttl-Rs232

2) Downloading section

3) Display unit

4) ADC interface

& many more

A unique Development board built around ATmega32 Is required.

Module a)

1) Sensor selection according to resolution and range->LM35

2) Signal condition circuit-

3) LCD interface

Module b)

To make it user friendly, Menu driven->tactile switches & LCD

Device protection circuitry

Module c)

Hooter and led indicator.

Logical approach:
17
 Module b) module will show 2 modes on display

1) Program mode

User can select parameter to be sensed & its convergent

factor

2) Run mode

Run mode is common for all modules or server

It just means server waiting for command from client & eager to respond.

2) RS-485 implementation

1) For level conversion needed for slaves ->

RS485 –TTl Transceivers (for slaves)

2) For level conversion needed for master ->

RS232-RS485 ->

A) RS232 to TTL and TTl to RS485 transceiver

B) RS232 to RS485 transceiver

3) Termination resistance selection->

3) SCADA system

1) Modbus Master- slave driver implementation

Programming language-visual basic

2) Graphics User Interface

18
 8. HARDWARE DESIGN

1) POWER SUPPLY DESIGN

19
 1N 4007 U 2

2
L M 7 8 0 5 C /T O
1 3
IN O U T
- +
Vin=24V 4 1

G N D
DC
Vout=5V

2
3
600uF 0 .3 3 u F 0 .1 u F
regulated

Fig 8.1

As shown in above diagram;

Bridge rectifier:

I/P=24V.

It is commonly used circuit for large amount of DC power. At one time two
diodes conduct simultaneously. We are using 1N4007 diodes.

Voltage drop=0.7*2=1.4V

So O/P of bridge rectifier is

24-1.4=22.6V.

Filters:

A circuit that removes ripples from a rectifier output without affecting DC voltage
is known as filter.

We are going to use capacitor filter. We will assume ripple factor as 5%.

We know;

Ripple factor= r=Vr(rms)/Vdc.

=Idc/4*31/2*f*C*Vdc

=1/4*31/2*f*C*RL

Substituting values;

20
 0.05 =1/ 4*31/2*f*C*RL

Now we have for our modules;

Idc=150mA

RL=5/150mA=33.33ohm

So we have

0.05= 1/ 4*31/2*f*C*33.33
C = 1732uF.

C=2200uF (standard).

IC7805:

From datasheet we have;

1. Wide input range: 7-35V

2. Max current capacity:1A

3.Output voltage : 5V regulated..

Then i/p of IC 7805 ;

Vdc=22.6v (I/P range for ic 7-35V)

Capacitors Cin and Co are used at input and output side of IC….

Need of capacitor:

1. Capacitor Cin filters out effects of stray inductance of input wire.

2. Output capacitor is generally not used but it improves the transient

of Regulator.

Power dissipation consideration:

We know from datasheet IC has max. PD=2W.

We know

Power dissipation =(Vin-Vout)*Io.

21
 We have

Io=150mA and Vin to 7805=22.6V

For max.2W PD we need

Vin-Vout=2W/0.5

=4V

But we have Vin-Vout =17.6V

So in our case PD will be

PD=17.6*150mA

PD =2.64W

Since we have more PD we NEED heat sink…

We are going to use general 25x50 mm Heat Sink which dissipates

power up to 3 watts.

2) Controller selection (ATMega32)

• 8-bit Microcontroller

• Advanced RISC Architecture

• Large amount of In-System Self-programmable Flash program memory

22
• At least 1K Bytes EEPROM

• Inbuilt 8-channel

• 10-bit ADC Programmable Serial USART

• Baud Rate achievable 115Kbps @ Fosc=3.6864MHz With 0% error

• Sophisticated IDE, Software tools like compiler, library

• Free downloading circuit and software

• Availability of prototype board

23
 mV between A and B data line.

Fig 8.2

As we know that using modbus we can connect up to 32 devises. so RS485

can have at max

32 nodes. In our case we are going to use 3 slaves and 1 master. So we have
4 RS485 Nodes.

Each RS 485 node has load impedance of 12K. so for such 4 nodes in
parallel give load of 3k.
24
 Minimum requirement of voltage between terminals A and B=200mV.

So to maintain this voltage the bias current required to flow through load is
given by

Bias current=200mV/(120||3K||120)

Bias current =3.4mA

Now to calculate bias resistance value we have;

3.4mA=5V/(2R+(120||3K||120))

2R+59=5V/3.4mA

2R+59=1470

2R=1411

R=705 ohm.

Value used=700 ohm

4) Transistor driver circuit for buzzer

5 V

4 0 0 o h m
L S 1

2
B U Z Z E R

R 2
1

5V 2
B C 5 4 7
4 7 K o h m
3

Fig 8.3

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

So
25
 Ic =10mA.

From datasheet; Vce=1V.

1. Applying KVL to C-E;

Vcc=Ic*R1+Vce

5=10mA*R1+1

R1=400 ohm.

For Ib we know;

Ib=Ic/Hfe(min).

From datasheet of BC547 we have;

Hfe(min)=110.

So,

Ib=10mA/110

Ib =90.90uA.

2. Applying KVL to B-E, we have

VIN=Ib*R2+Vbe

5=Ib*R2+0.7

4.3=Ib*R2

4.3=90.90uA*R2

R2=4.3/90.90uA

R2=47.3047Kohm.

So we have R1=400ohm and R2=47.3047kohm.

5)SIGNAL CONDITIONING

26
 Fig 8.4

For non inverting amplifier ;

Gain: 1+Rf/Ri.

Required gain: Vo/Vin:

=5/1.5

=3.333.

We will use Ri=1K… then we have

3.33=1+Rf/1K

Rf=2.33K..

We will use 10K pot as Rf.

So we have

Ri=1K and

Rf=10K(variable)…

Now for offset nulling technique as shown in figure…

We are going to use LM358 so Vcc=5V and from datasheet of that opamp we got value
of input offset voltage as 7mV(max)….
27
 V=Vcc=5V

Vios=(Rc/Rb)V

7mV= (Rc/Rb)5

Rb=1400Rc

Choose Rc as 20 ohm.. then we have

Rc=20ohm

Rb=1400*20

=28Kohm

Take Rmax=Rb/10 so

Rmax=2800

As we know Rmax=Ra/4

Ra/4=2800

Ra=11.2Kohm(this is variable one)

We can adjust this variable Ra till the output reaches to zero…..

28
 9. SOFTWARE DESIGN

Device Profile

Modbus Application layer

UART 29

RS-485
 Network layer

Fig 9.1

As per our system consider, We support following Functins:

Access Function
Primary Table Object type Type Reference Supported
Discrete Input Single bit Read Only 1x 0x2

Coil Single bit Read/Write 0x 0x1

0x5

Input Register 16 bit word Read Only 3x 0x4

Holding Register 16 bit word Read/Write 4x 0x3
0x6
0x10

Table 9.1

Exception Codes

Code Name Meaning

30
 The function code
01 received in the query is
ILLEGAL FUNCTION not an allowable action
for the slave. If a Poll
Program Complete
command was issued,
this code indicates that
no program function
preceded it.
The data address
02 received in the query is
ILLEGAL DATA not an allowable
ADDRESS address for the slave.

A value contained in the

03 query data field is not
ILLEGAL DATA VALUE an allowable value for
the slave.
An unrecoverable error
04 occurred while the
SLAVE DEVICE slave was attempting to
FAILURE perform the requested
action.
The slave has accepted
05 the request and is
ACKNOWLEDGE processing it, but a long
duration of time will be
required to do so. This
response is returned to
prevent a timeout error
from occurring in the
master. The master can
next issue a Poll
Program Complete
message to determine
if processing is
completed.

Table 9.2
Algorithms

Main for Module A :

1. Start
31
 2. Initialize all variable.

3. Initialize all Ports.

4. Initialize ADC.

5. Initialize UART for Baud rate 9600,no Parity,1 Start and 1 Stop
bit.

6. Init Timer0;

7. Enable USART_RXC Interrupt.

8. Set Global Interrupt Enable pin high.

9. Loop

10. Check sampling rate and log data into eeprom using internal
ADC

11. Go to step 9

Main for Module B:

1. Start

2. Initialize all variable.

3. Initialize all Ports.

4. Initialize ADC.

5. Initialize UART for Baud rate 9600, no Parity, 1 Start and 1

Stop bit.

6. Init Timer0;

7. Enable USART_RXC Interrupt.

8. Set Global Interrupt Enable pin high.

9. Loop

10. Check sampling rate and log data into eeprom using internal
ADC

32
 11. Go to step 9

Main for Module C

1. Start

2. Initialize all variable.

3. Initialize all Ports.

4. Initialize UART for Baud rate 9600,no Parity,1 Start and 1 Stop
bit.

5. Init Timer0;

6. Enable USART_RXC Interrupt.

7. Set Global Interrupt Enable pin high.

8. Loop

9. Go to step 9

ISR-RECIEVED COMPLETE

1. clear interrupt enable

2. disable USTART complete

3. initialize timer for 10usec

4. enable timer interrupt

5. received byte[count] = received byte

6. count = count +1

7. set delay count for 3.5msec

8. set interrupt enable

ISR-Transmission COMPLETE

1. Clear interrupt enable

33
 2. If Current= Byte to send then go to step 3

Else transmit que[current++];go ot step 4;

3. Disable transmit complete interrupt

TIMER 0 interrupt enable

4. Set interrupt enable.

ISR-Timer0

1. Clear interrupt enable

2. if delay counter ON go to step 3

3. if delay count2=0 then delay counter OFF

else delay count 2=delay count2 - 1

4. if delay count!=0, then delay count= delay count - 1

Go to step 7

5. if count=0, then no of bytes received = count

else go to step 7

6. if first received byte [0] = slave id

a) Call updateQue()

b) Enable USART transmission complete interrupt

c) Transmit Que[0]

d) Current = 1

7. Preset counter.

8. Send interrupts enable flag.

UpdateQue

1. Current = 0

2. Que(0) = slave id

3. If login, then go to step4 else go to step 6

34
 4. Check if exception

5. if exception

a) Que(1) = 80Hex + received byte [1]

b) Que(2) = Exception code

c) byte to send=3

d) return

6. if password wrong

a) send exception 4

b) return

7. Que(1) = received byte [1]

8. serve functions

9. return

STATE DIAGRAMs

UpdateQue()

Whenever Responding to any query wile updating Queue of Response frame it may be
Exception or Normal Response.

35
 Figure 9.2 : Modbus Transaction diagram.

Function 1

ENTR

MB Server receives mb_req_pdu

36
NO
Function code
Starting Address
ExceptionCode=04
0x0001≤quantity & Quantity
of Registers
MB ≤ of
Server Registers
Sends mb_rsp
ExceptionCode=01
MB Server NOExceptionCode=02
Sends NO
mb_exception_rsp
ExceptionCode=03 Request processing
Exit YESYES
YES
OK
0x007D
 YES
NO

ReadDiscreteOutp

Figure 9.3 : Read Coil state diagram

Function 2

ENTR

MB Server receives mb_req_pdu

37
NO
Function code

ExceptionCode=01 Starting Address

ExceptionCode=04
0x0001≤quantity & Quantity
of Registers
MB ≤ of
Server Registers
Sends mb_rsp
MB Server NOExceptionCode=02
Sends NO
mb_exception_rsp
ExceptionCode=03 Request processing
Exit YESYES
YES
OK
0x007D
 YES
NO

Read Discrete Inputs

Figure 9.4 : Read Discrete Inputs state diagram

Function 3

ENTR

MB Server receives mb_req_pdu

NO
38
Function code
YES
ExceptionCode=01
0x0001≤quantity of Registers ≤
Starting Address &
ExceptionCode=04
0x007D Quantity
Server of Registers
MB Server NOExceptionCode=02
Sends NO
mb_exception_rsp
ExceptionCode=03 Request MB
processing
Exit Sends mb_rsp
YESYES
YES
OK
 NO

ReadMultipleRegister

Figure 9.5 : Read Holding Register state diagram

Function 4

39
 Fig 9.6

Function 5

40

YES
 ENTR

MB Server receives mb_req_pdu

NO
Function code YES
NO
ExceptionCode=01
0x0001≤quantity of Registers ≤
0x007D
YES
ExceptionCode=03
Starting Address & Quantity of Registers
NO OK
ExceptionCode=02 YES
Request processing

WriteSingleOutput
NO YES
ExceptionCode=01
MB Server Sends mb_rsp

MB Server Sends mb_exception_rsp Exit

Figure 9.7 : Write Single Output state diagram

Function 6

41
 ENTR

MB Server receives mb_req_pdu

NO
Function code
YES
ExceptionCode=01
0x0001≤quantity of Registers ≤
NO
0x007D
ExceptionCode=03 YES
Starting Address & Quantity of Registers
NO OK
ExceptionCode=02
YES
Request processing

WriteSingleRegister
NO
YES
ExceptionCode=04
MB Server Sends mb_rsp

MB Server Sends mb_exception_rsp Exit

Figure 9.8 : Write Single Register state diagram

Data address allotment

Module A :

s.n. Task Data model Access Start address Ending address

Holding
1 Enter passwod Register R/W 400020 400024
42
 2 Login Status Input Coil R/O 100001
3 Logoff Output coil R/W 000010
4 Current data Input Register R/O 300001
Holding
5 Sample rate Register R/W 400100 400102
Hour 400100
Minute 400101
Seconds 400102
Retrieve logged
6 data Output coil R/W 000001
7 No. valid loggs Input Register R/O 300002
8 Access nth log Input Register R/O 301000 304999
Holding
9 Choose unit Register R/w 400002
Table 9.3

Module B :

s.n. Task Data model Access Start address Ending address

Holding
1 Enter passwod Register R/W 410020 410024
2 Login Status Input Coil R/O 110001
3 Logoff Output coil R/W 010010
4 Current data Input Register R/O 310001
Holding
5 Sample rate Register R/W 410100 410102
Hour 410100
Minute 410101
Seconds 410102
Retrieve logged
6 data Output coil R/W 010001
7 No. valid loggs Input Register R/O 310002
8 Access nth log Input Register R/O 311000 314999
9 Read unit Input Register R/O 313002
10 Scaling Factor Input Register R/O 312000
Table 9.4

Module C:

Start Ending
s.n. Task Data model Access address address
Holding
1 Enter passwod Register R/W 420020 40024
2 Login Status Input Coil R/O 120001
43
 3 Logoff Output coil R/W 20001
4 Buzzer Output coil R/W 20020
5 LEDs Output coil R/W 20100 20102
Table 9.5

Calculations:

Timer 0 interrupt for 100uS:

TCCR0 = 0x02;

Resultant clock source after multiplier = Fcrystal/8.

Fclk = 3.6864MHz/8=460.8KHz.

TCNT0 = 210;

Resultant time=(256-TCNT0)/Fclk

=46/460.8K

=100uSec.

UART:

UBRR Settings for 3.6864MHz crystal.

Ref:Page166 Table 69 AtMega32 datasheet ,for 0% error up to 230.4K

baud rate.

Delay count for Time Out:

MODBUS Message RTU Framing

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

44
In RTU mode, message frames are separated by a silent interval of at least 3.5
character times. In the following sections, this time interval is called t3,5.

Fig 9.9

Specifically, about 9600 baud rate.

In 9600 Baud rate each bit takes 1/9600 seconds to transmit.

For whole frame (Normal)= 1 start+1 stop+8 data bits=10bits=>

So require 10*1/9600 seconds. Which is time taken for transmitting 1 char

so for 3.5 char time taken will be=10*3.5/9600=3.5mSec.

For 3.5 msec with help of 100usec Interrupt popping out .

So ,we require 3.5m/100u=35 as Delay count.

SCADA Design:

45
SCADA usually starts with login process and after that continuously monitor for
expected information. While designing there are many free SCADA’s available to use
with MODBUS like-> Modscan32, SimplyModbus6.3.6 (Master) & very useful Docklight.

First of all we tried with Docklight

Wrong Id, wrong password, password ….

At the last, Logoff.

46
 Expected GUI ( Font end) under VB2008

Algorithm followed->

1. Select device from user. Generate slave ID accordingly.

2. Check login status, if login then continuously monitor for current reading.

3. Else ask for password. Unless right one is not entered.

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

10. APPLICATIONS

47
 • process control
• Factory floor automation
• Manufacturing process
• Industrial process automation
Industrial process automation: Press Forging

Press forging
Forging is one of the oldest known metalworking processes

In modern times, industrial forging is done either with presses or with hammers powered
by compressed air, electricity, hydraulics or steam. These hammers are large, having
reciprocating weights in the thousands of pounds.

Press forging is an operation characterized by the process of deformation which

consists of a lot of heating and cooling. During the process, the material is slowly
condensed into a shape by increasing pressure. There are two dies; one stationary and
one pushed towards the other, which compresses the part. Press forging is variation of
drop-hammer forging. Unlike drop-hammer forging, press forges work slowly by
applying continuous pressure or force. The main advantage of press forging, as
compared to drop-hammer forging, is its ability to deform the complete work piece

MODBUS
2 4
Pc Over RS485 Vin (condition: 0v<Vin<5v)
based 3 8

SCADA 2 5 Pressure sensor

&
Generic
Conditioning
Device

Temperatur
e Conversion GND
Module
Factor

Process
status
Fig 10.1

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

48
It should be noted that production input billet casting is the beginning point of the
manufacturing process which eventually yields the various wrought forms of beryllium
copper.

C82500 BeCu Cast

Electronic
Component

Beryllium copper application:

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

11.TESTING:
Communication
49
 *For all serial communication purpose DOCKLIGHT Ver.1.6 s/w used.

RS232 Driver Implementation:

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

• Serial Communication with pc

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

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

received on PC

50
RS485 Driver Implementation:

• Circuit Design & PCB:

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

• Serial Communication with pc as half duplex

Using 2nd PCB in Fig Transmission lines are shorted so as to get back
echo on PC.

• Serial Communication with pc as full duplex

Both PCB’s from Fig are used, one for Master side and another for slave
side, so that 100 bytes sent from controller received on PC

Driver circuitry for Buzzer

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

51
 XMM1
VCC
5V
R1
XMM2
4.3k
R2
390
Q1
R3

47k
BC547BP

Temperature sensing: LM35

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

While implementing Timer on timer0 using 2 LED’s connected to 2 pin and

implementing toggling algorithem timer of 100usec was verified.

SCADA testing:
52
SCADA tested using Modscan32.exe a freeware SCADA.

12.FUTURE SCOPE
53
• We have used 4 wire interface for implementing RS485 . Instead of that
we can make use of 2 wire interface. But for that we have to define
directional logic which is necessary for that system interface.

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

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

DCS.

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

Isolation”

54
 13. BIBLOGRAPHY
BOOKS

[Boye] Electronic Devices and Circuit Theory.

8th Edition.Robert Boylestad.

Prentice Hall India

[Mazi] The 8051 Microcontroller and Embedded Systems

2nd Edition, Muhammad Mazidi

Pearson Education

[JanS] Serial Port Complete

Penram International Pvt. Ltd.
2nd Edition, Jan Axleson

[Dhan] Programming and customizing the AVR microcontroller-Dhananjay V.

Gadre

APPLICATION NOTES

*Modicon.com

[AN001] MODBUS APPLICATION PROTOCOL SPECIFICATION V1.1b

[AN002] MODBUS over Serial LineSpecification and Implementation Guide
V1.02
[AN003] Modicon Modbus Protocol Reference Guide PI–MBUS–300 Rev. J

*Texas Instruments
[SLLA272B] The RS-485 Design Guide February 2008–Revised May 2008

*Maxim-IC

[AN1063] Microcontroller Recognizes Addresses in RS-485 Systems

[AN736] RS-485 (EIA/TIA-485) Differential Data Transmission System Basics

*Analog Devices

[AN960] RS-485/RS-422 Circuit Implementation Guide by Hein Marais

55
 14. APPENDIX
MODBUS @

The following figure gives a general representation of MODBUS serial communication

stack compared to the 7 layers of the OSI model with respect to our system..

Fig 14.1

Application layer

• Data Encoding
MODBUS uses a ‘big-Endean’ representation for addresses and data
items. This means that when a numerical quantity larger than a single byte
is transmitted, the most Significant byte is sent first.

• MODBUS data model

MODBUS bases its data model on a series of tables that have
distinguishing characteristics.

56
The four primary tables are:

Primary table Object Type of Comments

type access

coils Single bit Read- This type of data can be alterable by

Write an application program

Input registers 16-bit word Read-Only This type of data can be provided by
an I/O system

Holding 16-bit word Read- This type of data can be alterable by

registers Write an application program

Discrete Input Single bit Read-Only This type of data can be provided by
an I/O system

Table 14.1

Data link layer:

1) MODBUS frame description

The MODBUS protocol defined a simple protocol data unit (PDU) independent of
the underlying communication layers. The mapping of

MODBUS protocol on specific buses or network can introduce some additional

fields on the application data unit (ADU).

General MODBUS frame:

ADU

ADDITIONAL FUNCTION
DATA ERROR CHECK
ADDRESSES CODE

57
 PDU

Fig 14.2

The function code 1 byte. (128 – 255 reserved for exception responses).

Max size:

RS485 ADU = 256 bytes.PDU for serial line communication = 253 bytes

Server address (1 byte) , CRC (2 bytes)

2) MODBUS addressing rules:

Fig 14.3

3) The two serial Transmission Modes

Two different serial transmission modes are defined: The RTU mode and the
ASCII mode.

It defines the bit contents of message fields transmitted serially on the line. It
determines how information is packed into the message fields and decoded.

The transmission mode (and serial port parameters) must be the same for all
devices on a MODBUS Serial Line.

58
General 4 wire topology.

Fig 14.4

59
CRC CALCULATIONS

Fig 14.5

Table 15.1: COMPONENT LIST AND BILL

SR COMPONENT SPECIFICATIONS QTY COST (Rs)

NO

1 IC 7805 5V regulator 3 18

2 IC ATMEGA32 40-pin DIP 3 435

ICMAX232 16-pin-DIP 1 25

ICMAX485 8-pin DIP 8 320

ICLM35 TEMPERATURE 1 40

60
 SENSOR

ICLM324 Quad OpAmp 2 20

3 IC base 16 pin dip 3 6

40 pin dip 3 12

8 pin dip 8 8

4 Relamet connector 6 pin 1 9

2 pin 6 12

5 Transistor BC547 1 1

6 Toggle switch SPDT 3 24

7 Zener diode 5.1 V 2 2

8 Diode 1N4007 16 16

9 Resistors 1K ohm 0.25watt 12 3

10 kohm 0.25watt 2 0.5

15 Kohm 0.25watt 1 0.25

4.7 kohm 0.25 watts 2 0.5

120ohm0.25watts 4 1

47Kohm0.25watts 1 0.25

680ohm0.25watts 4 1

20ohm0.25watts 4 1

402ohm0.25watts 1 0.25

10. Variable Pot 10k,1k precesion 2 8

11. Capacitors 1000uF,25V,electrolytic 1 6

100 uF,25V,electrolytic 1 2

10uF 25V, electrolytic 4 4

0.01 uF,22pF ceramic 10 10

2200uF, electrolytic 2

61
12. Bur strips 40 pin 3 18

13. 2 pin push button 1 2

14 LEDs 3mm 10 10

15 PCB

16 Serial cable Plug socket DB9 1 75

17. DB 9 socket Female 2 20

18. Crystal 3.6864Mhz 1 15

19. casing

20. BUZZER 3V-24V 1 21

TOTAL

15. CIRCUIT DIAGRAM

62
MODULE C
5V

1 .8 K

1 .8 K LED
400 ohm LS1
U 1 1 .8 K LED
1
b u zzer
1 40 LED
2 2 P B 0 /XC K 0 /T 0 P A 0 /A D C 0 39 1 .8 K LED
3 P B 1 /T 1 P A 1 /A D C 1 38 1 .8 K
BU ZZER
4 P B 2 /IN T 2 /A IN 0 P A 2 /A D C 2 37
P B 3 /O C 0 /A IN 1 P A 3 /A D C 3 36 1 .8 K LED
5 P A 4 /A D C 4 35
5V 6 P B 4 /S S P A 5 /A D C 5 34 LED
R 2 7 P B 5 /M O S I P A 6 /A D C 6 33
1

bu zze r P B 6 /M IS O P A 7 /A D C 7
2 8 5V
BC 547 C 3 P B 7 /S C K 32
47 Kohm 0 .1 u F 9 A re f 31
R ESET G N D 30 C 3
AVC C
3

10 0 .1 u F
11 VC C
G N D
12
Y 1 13 XTA L2 29 C 3
C R Y S TA L XTA L1 P C 7 /T O S C 2 28 5V 0 .1 u F
22pF 14 P C 6 /T O S C 1 27
R x D _ in P D 0 /R x D P C 5 /TC I
15 26 U 3
C 2 T x D _ in P D 1 /T x D PC 4TD O 25
P C 3 /T M S T x D _ in
16 24 4 1
17 P D 2 /IN T 0 P C 2 /T C K 2 D I R O 6
P D 3 /IN T 1 R E A A T x _ in
3 7
C 1 D E B B T x _ in
18 23
19 P D 4 /O C 1 B P C 1 /S D A 22 8
20 P D 5 /O C 1 A P C 0 /S C L +VC C
22pF 21 P D 6 /IC P 1
P D 7 /O C 2 M A X485

D IP 4 0 JP1
A T x _ in 1
B T x _ in 2
A R x _ in 3
B R x _ in 4
4 H EAD ER

U 4
R x D _ in
4 1
2 D I R O 6
R E A A R x _ in
3 7
D E B B R x _ in
8
+VC C
0-5V
M A X485

5v C 3
0 .1 u F

63
 Fig 15.1

MODULE B

5V 5V

5V C 3

1
0 .1 u F 2 5K ohm
C 3
R 1 U 3A R 1 0 .1 u F
8

3
+ R b
1 5V
R _ in
3
2
-
LM 358 1K ohm
2

3
4

R c
C 1 2
U 1 R a
1

1 4 0
2 P B 0 /XC K 0 /T0 P A 0 /A D C 0 3 9
P B 1 /T1 P A 1 /A D C 1
1

3 3 8
4 P B 2 /IN T 2 /A IN 0 P A 2 /A D C 2 3 7
P B 3 /O C 0 /A IN 1 P A 3 /A D C 3 3 6
5 P A 4 /A D C 4 3 5
5V 6 P B 4 /S S P A 5 /A D C 5 3 4 5V JP1
7 P B 5 /M O S I P A 6 /A D C 6 3 3
P B 6 /M IS O P A 7 /A D C 7 A T x _ in 1
8 C 3
P B 7 /S C K B T x _ in 2
32
R _ in A re f A R x _ in 3
C 3 9 31 0 .0 1 u F
R ESET G N D B R x _ in 4
30
0 .1 u F 10 AVC C
C 2 22pF 11 VC C
G N D
12 5V U 6 M A X485
C R Y S TAL Y 1 13 XTA L2 2 9
C 1 XTA L1 P C 7 /T O S C 2 T x D _ in
22pF 2 8 4 1
14 P C 6 /T O S C 1 2 7 2 D I R O 6
R x D _ in P D 0 /R x D P C 5 /TC I R E A A T x _ in
15 2 6 3 7
T x D _ in P D 1 /Tx D PC 4TD O D E B B T x _ in
2 5 C 3
16 P C 3 /TM S 2 4 8
17 P D 2 /IN T 0 P C 2 /TC K 0 .1 u F +VC C
P D 3 /IN T 1 5V
1 8 23
1 9 P D 4 /O C 1 B P C 1 /S D A 22 U 6 M A X485
2 0 P D 5 /O C 1 A P C 0 /S C L
2 1 P D 6 /IC P 1 4 1
P D 7 /O C 2 D I R O R x D _ in
2 6
R E A A R x _ in
3 7
D E B B R x _ in
D IP 4 0
8
C 3 +VC C
0 .1 u F

64
 Fig 15.2

MODULE A
5V U 4 5V
0 .1 u F
2 1
VO U T VS+
5V C 3

0 .1 u F C 3
0 .1 u F
R 1 U 3A L M 3 5 /T O
8

3 5V
+ R 3
1 R b
R _ in
2
-
1K ohm

1
LM 358
2

R c 2
4

C 1 R a
U 1
1

1 4 0
P B 0 /XC K 0 /T0 P A 0 /A D C 0

3
2 3 9
3 P B 1 /T1 P A 1 /A D C 1 3 8
4 P B 2 /IN T 2 /A IN 0 P A 2 /A D C 2 3 7
P B 3 /O C 0 /A IN 1 P A 3 /A D C 3 3 6
5 P A 4 /A D C 4 3 5
5V 6 P B 4 /S S P A 5 /A D C 5 3 4 5V JP1
7 P B 5 /M O S I P A 6 /A D C 6 3 3
P B 6 /M IS O P A 7 /A D C 7 A T x _ in 1
8 C 3
P B 7 /S C K B T x _ in 2
32
R _ in A re f A R x _ in 3
C 3 9 31 0 .0 1 u F
R ESET G N D B R x _ in 4
30
0 .1 u F 10 AVC C
C 2 22pF 11 VC C
G N D
12 5V U 6 M A X485
C R Y S TAL Y 1 13 XTA L2 2 9
C 1 XTA L1 P C 7 /T O S C 2 T x D _ in
22pF 2 8 4 1
14 P C 6 /T O S C 1 2 7 2 D I R O 6
R x D _ in P D 0 /R x D P C 5 /TC I R E A A T x _ in
15 2 6 3 7
T x D _ in P D 1 /Tx D PC 4TD O D E B B T x _ in
2 5 C 3
16 P C 3 /TM S 2 4 8
17 P D 2 /IN T 0 P C 2 /TC K 0 .1 u F +VC C
P D 3 /IN T 1 5V
1 8 23
1 9 P D 4 /O C 1 B P C 1 /S D A 22 U 6 M A X485
2 0 P D 5 /O C 1 A P C 0 /S C L
2 1 P D 6 /IC P 1 4 1
P D 7 /O C 2 D I R O R x D _ in
2 6
R E A A R x _ in
3 7
D E B B R x _ in
D IP 4 0
8
C 3 +VC C
0 .1 u F

65
 Fig 15.3

Master: Module D
9 8 7 6
VC C
5V
9 8 7 6
5 4 3 2 1
705
5 4 3 2 1 U 7
R xD A T x _ in
4 1
2 D I R O 6
TxD _out 3 R E A 7 120
R xD _out D E B
8
+VC C B T x _ in
R 2
M A X 4 8 5 /S O
U 2 JP2
13 12
R xD _out R 1 IN R 1 O U T A R x _ in 1
8 9
R 2 IN R 2 O U T R xD B R x _ in 2
11 14
TxD T 1 IN T1 O U T A T x _ in 3
10 7
T 2 IN T2 O U T TxD _out B T x _ in 4
1 0 m ic r o F
1 5V 4 H EAD ER
3 C +
4 C 1-
1 0 m ic r o F 5 C 2+
2 C 2- 705
6 V +
V -
1 0 m ic r o F M A X232 U 8
TxD
1 0 m ic r o F
A R x _ in
4 1
2 D I R O 6 120
3 R E A 7
D E B
8
+VC C B R x _ in
5V

M A X 4 8 5 /S O

VC C
705

RS485 to RS232 conversion on master side(PC)

66
Fig 15.4

67
Layout of basic Prototype board

68
69
16. DATA SHEETS

70