HydroCOM

Edition 4.18

CIU - Operating Instructions

HydroCOM 4.1

CIU Operating Instructions 4.18.doc 2018-07-13

1 INTRODUCTION ................................................................................................... 4

2 ABBREVIATIONS ................................................................................................. 4

3 GENERAL FUNCTION .......................................................................................... 5

3.1 What is the task of the CIU? .................................................................................................................. 5

3.2 Design of the CIU .................................................................................................................................... 6

3.3 Description of CIU components ............................................................................................................ 7

3.3.1 SIM-4 Stage Interface Module .......................................................................................................... 7
3.3.2 GIM-4 General Interface Module ...................................................................................................... 7
3.3.3 IPS Internal Power Supply ................................................................................................................ 7

3.4 Description of associated parts ............................................................................................................ 8

3.4.1 External Power Supply ..................................................................................................................... 8
3.4.2 Isolation Amplifier ............................................................................................................................. 8
3.4.3 Transmitter Supply Isolator ............................................................................................................... 8

4 CONFIGURATION OF THE DCS, GENERAL COMMENTS................................. 9

4.1 Control Strategy (not part of the CIU) ................................................................................................... 9

4.2 Interface DCS - CIU: hard-wired .......................................................................................................... 10

4.3 Interface DCS - CIU: via MODBUS ....................................................................................................... 10

5 MONITORING OF THE CIU DURING NORMAL OPERATION .......................... 11

5.1 General .................................................................................................................................................. 11

5.2 Error Code ............................................................................................................................................. 11

5.3 How to classify an error code and how to clear it ............................................................................. 12

6 ERROR CORRECTION....................................................................................... 13
6.1 Error Table SIM ..................................................................................................................................... 13

6.2 Error Table Actuator ............................................................................................................................. 14

6.3 Error Correction SIM ............................................................................................................................ 15

6.3.1 Error x.. – No configuration ............................................................................................................. 15
6.3.2 Error x01 - RS485 Malfunction ....................................................................................................... 15
6.3.3 Error x02 - Type mismatch ............................................................................................................. 15
6.3.4 Error x03 - Transmission Error RS485 ........................................................................................... 16
6.3.5 Error x04 - Invalid Parameters ........................................................................................................ 16
6.3.6 Error x05 - Low Voltage .................................................................................................................. 17
6.3.7 Error x06 - Invalid Control Variable ................................................................................................. 17
6.3.8 Error x07 - TDC Timeout ................................................................................................................ 17
6.3.9 Error 10d – Maintenance reminder ................................................................................................. 18

6.4 Error Correction Actuator .................................................................................................................... 19

6.4.1 Error xy0 – Failure of an Actuator ................................................................................................... 19
6.4.2 Error xy1 - Hydraulic Pressure Too Low (Errors only possible for systems before 2003) .............. 19
6.4.3 Error xy2 - Supply Voltage below 39 V ........................................................................................... 20

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 6.4.4 Error xy4 - Short Circuit in Solenoid Circuit .................................................................................... 20
6.4.5 Error xy5 - Line Break in the Solenoid Circuit ................................................................................. 21
6.4.6 Error xy6 - Failure Temperature Sensor ......................................................................................... 21
6.4.7 Error xy7 - Failure Hydraulic Pressure Sensor ............................................................................... 21

7 MODBUS COMMUNICATION............................................................................. 22
7.1 Definition of the MODBUS protocol .................................................................................................... 22
7.1.1 ID - Address .................................................................................................................................... 23
7.1.2 Transmission Medium .................................................................................................................... 23
7.1.3 Baud-Rate ...................................................................................................................................... 23
7.1.4 Parity .............................................................................................................................................. 23
7.1.5 Stop-Bit ........................................................................................................................................... 23
7.1.6 Transmission Mode ........................................................................................................................ 23
7.1.7 Error detection ................................................................................................................................ 24
7.1.8 Data and Control Functions ............................................................................................................ 24
7.1.9 Exception Response ....................................................................................................................... 25
7.1.9.1 Function Code Field ................................................................................................................... 25
7.1.9.2 Data field .................................................................................................................................... 25

7.2 Parameters and Registers of HydroCOM 4.1 ..................................................................................... 26

7.2.1 General Specification - Parameters ................................................................................................ 26
7.2.2 Data Registers ................................................................................................................................ 28
7.2.2.1 Read Only Registers (Input Registers) ....................................................................................... 28
7.2.2.1.1 CIU Status ............................................................................................................................ 28
7.2.2.1.2 Actual Binary Inputs (hardwired or MODBUS-controlled)..................................................... 28
7.2.2.1.3 Actual Control variables (hardwired or MODBUS-controlled)............................................... 28
7.2.2.1.4 Actual Speed ........................................................................................................................ 29
7.2.2.1.5 Operating Hours ................................................................................................................... 29
7.2.2.1.6 Days to next service (=Maintenance) ................................................................................... 29
This value will be displayed as decimal number from 0-4094. ............................................................... 29
7.2.2.1.7 SIM Status ............................................................................................................................ 30
7.2.2.1.8 Actuator Status ..................................................................................................................... 31
7.2.2.1.9 Temperature Values Actuator .............................................................................................. 31
7.2.2.1.10 Message Memory SIM ....................................................................................................... 32
7.2.2.2 Read / Write Registers (Holding Registers)................................................................................ 33
7.2.2.2.1 Control variable (SIM1 through SIM6) .................................................................................. 33
7.2.2.2.2 Digital Inputs (GIM) .............................................................................................................. 33
7.2.2.2.3 Free addressable Write Registers ....................................................................................... 34

7.3 Configuration of MODBUS connections ............................................................................................. 35

7.4 Programming of a MODBUS Master ................................................................................................... 36

7.4.1 Evaluation of Register Information ................................................................................................. 36
7.4.1.1 Example: Register 30001 ........................................................................................................... 36
7.4.1.2 Example: Register 30626 ........................................................................................................... 37
7.4.2 Functions (examples) ..................................................................................................................... 38
7.4.2.1 04 Read Input Register ............................................................................................................... 38
7.4.2.2 08 Diagnostic function only for CIU 2.0 ..................................................................................... 39
7.4.3 Error detection ................................................................................................................................ 40
7.4.3.1 CRC ............................................................................................................................................ 40
7.4.3.2 LRC ............................................................................................................................................ 41

CIU Operating Instructions 4.18.doc 3 2018-07-13

1 Introduction
The CIU operations instruction explains briefly function, design and
operation of the HydroCOM CIU. Another document of the customer
handbook (“Controller specification”) explains the application specific
control strategy and is not part of this document. Dimensions and technical
data of the components of the CIU are found in the installation manual.

Attention: Wrong configuration or wrong programming

of the Compressor Interface Unit or the DCS
may lead to irreversible damage of the
HydroCOM-System and the compressor!

"This document comprises a general overview of the products described

herein. It is solely for informational purposes and does not represent a
warranty or guarantee. Contact HOERBIGER for detailed design and
engineering information suitable to your specific application. HOERBIGER
reserves the right to modify its products and related product information at
any time without prior notice."

2 Abbreviations
The following abbreviations will be used throughout this manual

Actuator unit for the actuation of the suction valves

CA Crank Angle (in degrees)
CIU Compressor Interface Unit
DCS Control System: either Distributed Control System,
programmable logical controller or programmable loop
controller
EPS External Power Supply
GIM General Interface Module
HSS HydroCOM Service Software
HU Hydraulic Unit
IA Isolation Amplifier
IPS Internal Power Supply
LED Light Emitting Diode
PLC Programmable logical controller
SIM Stage Interface Module
TDC Top Dead Center
TSI Transmitter Supply Isolator

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3 General Function
3.1 What is the task of the CIU?
Below figure shows schematically a typical HydroCOM system architecture.
Compressor control is carried out in the DCS. Per compressor stage a
control loop has to be realized. These control variables are forwarded to the
compressor interface unit (CIU). The CIU translates the control variables
into HydroCOM specific data, which are forwarded to the HydroCOM
actuators via bus lines. Each actuator controls a suction valve according to
the instructions taken from the bus. Consequently the load of the
compressor is controlled. To achieve that a top-dead-center (TDC) sensor
is required to trigger the control variables with each crank-shaft revolution.

Control can be done either by a DCS, PLC or a loop controller.

Binary signals (Error, Maintenance) indicate general status of the
HydroCOM system and are available to the DCS.

Each actuator has a temperature sensor installed in the seal housing.

These readings are transmitted over the bus line to the CIU, which can be
accessed by the DCS.

Fig.1: general view HydroCOM

An IBM compatible PC (RS-232-interface) can be connected to the CIU via

the HSS-interface. It is used to configure the CIU and for maintenance.

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3.2 Design of the CIU
The Compressor Interface Unit consists of up to 6 control modules (SIM
Stage Interface Module), an interface module GIM (General Interface
Module) and the internal power supply IPS. These modules are placed in a
19” sub-rack. Further an isolation amplifier (IA), up to 2 transmitter supply
isolators and a 48VDC external power supply EPS are related to the CIU
and located next to it.

HOERBIG HOERBIG HOERBIG HOERBI HOERBIG HOERBI

ER ER ER GER
CIU on
ER GER
TDC 5V
Enable
Code Code Code Simulation
Maintenance 15V
Error
Phyd low

Scroll/ Scroll/ Scroll/

Clear Clear Clear
HSS HydroCOM

SIM-4 SIM-4 SIM-4 GIM-4 CIU-4 IPS

Fig.2: Front view CIU

Fig. 3 shows the Plug-in terminals for connection of the cables in the control
cabinet.

Modbus interfaces SIM interfaces

binary GIM inputs binary GIM outputs load signal (4…20mA) per SIM

CIU mains connection

Fig.3 : Rear view CIU

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3.3 Description of CIU components
3.3.1 SIM-4 Stage Interface Module
A SIM controls all the actuators of one stage, i.e. up to 8 units. Head End
and Crank End valves can be controlled individually. There must be one
bus line to the compressor for each SIM. This data line connects the
actuators of one stage to the corresponding SIM. Subsequently all actuators
are supplied with data by the SIM at their specific address and measured
signals can be transferred from the actuators to the CIU.
The load signals given by the DCS are converted to timing signals for the
single solenoids in the actuators. As already explained in the manual
"General Description", HydroCOM controls the delivered volume of the
compressor by keeping the suction valves open.
In order that the control module can address all suction valves of one stage,
a specific data set which reflects the model and operating mode of the
compressor, must be configured (cf. HSS-operating manual). The
configuration will be done by HOERBIGER.

3.3.2 GIM-4 General Interface Module

The module makes available the binary outputs ERROR, MAINTENANCE
and HYDRAULIC PRESSURE LOW and accepts the binary signals
ENABLE and SIMULATION, as well as the top dead center signal (TDC).
Besides the operation and error signal indicators the serial interface for the
HSS (HydroCOM Service Software) is arranged on the face plate.
This module stores the configuration data. When it is exchanged, the
configuration has to be loaded again by means of the HSS.

3.3.3 IPS Internal Power Supply

This module provides the supply voltage for the electronics in the CIU. The
correct functioning is indicated by the green LEDs 5V and 15V. The supply
voltage is 93-250VAC with 50-60 Hz.

Fig.4: Front view (partial)

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3.4 Description of associated parts
3.4.1 External Power Supply
The External Power Supply EPS provides 48VDC for the actuators.

3.4.2 Isolation Amplifier

The isolation amplifier transfers the pulses of the TDC sensor out of the
potentially explosive area. A proximity switch is connected to the input. The
output port 1 is connected to the CIU. The CIU calculates the momentary
crank angle and the speed from the TDC sensor signal, which gives one
impulse at each turn. Input ports, output ports and supply voltage are
electrically separated from each other.

3.4.3 Transmitter Supply Isolator

The device is suited for the connection of 2- and 3-wire transmitters. They
may also be used as repeaters for 0/4mA…20mA signals (current source).
These transmitter supply isolators have to be used for the temperature and
pressure transmitter installed on the Hydraulic Unit. For each transmitter a
TSI is necessary.

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4 Configuration of the DCS, General comments
4.1 Control Strategy (not part of the CIU)
The compressor is either controlled by the distributed control system or by
an external loop controller optionally provided by HOERBIGER.

One of the process variables (e.g. discharge pressure, suction pressure,

flow volume..) is selected as control variable. The user defines a set point
for this variable. A PI controller is assigned to each stage of the
compressor. The first stage is controlled according to the process variable.
The output of the first controller operates primarily the first stage. The
interstage suction pressures are selected as control variables for the higher
stages. The capacity delivered by each stage is varied by 4..20mA
corresponding to approx. 0..100% controller signals which are sent to the
CIU. Fig.5 shows this principle. A start-up function for the start-up phase
may be provided in the DCS configuration. It includes a start-up unloading
function and a start-up ramp in order to obtain smooth loading of the
compressor after start-up.

Fig 5: principle scheme of suction control

Optionally HOERBIGER can either give assistance with the configuration of

the DCS

CIU Operating Instructions 4.18.doc 9 2018-07-13

4.2 Interface DCS - CIU: hard-wired
In order to simplify the integration of the compressor into the DCS / PLC
and to simplify the design of the PI-controllers, the following table shows all
the input and output signals of the process control system, which are
necessary for the operation of HydroCOM. A detailed description is included
in the Assembly and Installation Instructions.

Input signals Function Signal type

control variable Sends the momentary control 4 .. 20 mA

(one per SIM) variable (load signal of the see chapter 4.1
compressor) from the DCS to
the CIU

Enable The HydroCOM system can be 0/24V, or isolated contact; or

turned on or off from the DCS transistor output (OC)

Simulation Starts the simulation mode of 0/24V, or isolated contact; or

the HydroCOM from the DCS transistor output (OC)

Output signals Function Signal type

Phyd Low Is triggered if the hydraulic Source is an isolated contact; in

pressure goes below the case of active signal the contact is
programmed limit value interrupted

Maintenance The maintenance condition is Source is an isolated contact; in

sent to the DCS in case of a case of active signal the contact is
failure of a sensor (Actuator) or interrupted
if the operating hours / date are
reached

Error The message is triggered and Source is an isolated contact; in

transmitted to the DCS in case case of failure the contact is
of an error condition interrupted

Measuring Signals measuring signals of the 4 .. 20mA

(valve cover actuators are transmitted to the (for suction valve temperatures:
temperatures) DCS as analogue signals 4mA equals -25°C
20mA equals 125°C)

4.3 Interface DCS - CIU: via MODBUS

Data exchange between CIU and DCS can be provided via Modbus
Interface. There are 2 MODBUS interfaces, one for Control and one for
Monitoring.
For detailed information on the MODBUS Protocol see chapter 7.

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5 Monitoring of the CIU during normal operation
5.1 General
The monitoring of the CIU during normal operation includes essentially two
items:

 Checking of configuration:
The checking of the configured parameters - especially after operating
conditions have changed - can only be done with the assistance of the
HSS (cf. HSS operating instructions).

 Classification of error messages and resetting:

HydroCOM has a self-diagnostic system. Components and signals
essential for the function are checked and the respective error
messages are shown on the face plate. Such errors are transferred to
the DCS by the CIU with the signals Maintenance, Error, or Hydraulic
Error.

5.2 Error Code

Each report can be uniquely attributed to an error at a SIM or actuator. The
error code consists of 3 digits, which are displayed at the front of the SIM:

 The first digit indicates the number of the SIM or stage respectively

 The second digit shows where the error has occurred:

 0 ... standing for an error in the SIM itself
 1 ... standing for an error in Actuator 1
 2 ... standing for an error in Actuator 2
 and so on

 The rightmost digit shows which error has occurred:

 it ranges from 1 to 8
 the codes are explained below

 Errors at SIMs and Actuators have a different cause, that means that the
error 101 and 111 is different in both, place of error and cause of error.

 Each message activates a relay output to the DCS. There are three
outputs: Error, Maintenance und Phyd low which are activated depending
of the sort of message.

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5.3 How to classify an error code and how to clear it
After appearance of the error or maintenance display at the process control
system you can classify the errors at the CIU (cf. Fig.2) and treat them
systematically as follows:

 Make a list of errors. Enter the error which occurred for each SIM and
each Actuator of the respective SIM with the 3-digit code:
 st
1 digit shows the SIM number
 2
nd
digit shows the place of error
 rd
3 digit shows the kind of error
 The display shows the error first occurred.
 By pressing the button below the error display you can change to the
next error message.
 After having noted all the errors you can clear all the error messages
from the memory by pressing and holding the button for 3-4 sec.
 Error messages will immediately occur again after Clear, if the error
condition is still valid.
 If the CIU reports an error to the DCS, the diode Error is on.
 If the CIU reports maintenance to the DCS, the diode Maintenance is
on.
 If the CIU receives the simulation signal from the DCS, the diode
Simulation is on.
 If the CIU receives the signal Enable from the DCS, the diode Enable is
on.
 The diode TDC flashes with working TDC-sensor.
 The diode CIU on shows that the CIU is operating.

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6 Error Correction
Remarks concerning the sections below:
 The “Error code” remains stored, until it is cleared either by push
button, HSS or MODBUS.
 “LED and output” are at the GIM, the marking of the output terminals
on the backplane is in brackets.
 The last column “Error reset condition” indicates the condition that will
make the error disappear.

6.1 Error Table SIM

Error Error cause LED and Error reset condition

code Output

X.. No configuration on CIU Error (ER) Parameters configured on CIU with

HSS

X01 RS485 bus defective (error Error (ER) correct data transfer between CIU
on data line between SIM and field devices
and actuator, bus conflict,
short circuit)

X02 Type mismatch Error (ER) Correct configuration of devices and

power off/on for CIU

X03 Transfer error RS485 bus Error (ER) correct data transfer between CIU
(check sum error) and actuator

X04 invalid parameters on CIU Error (ER) new configuration of CIU

X05 low voltage 15V or Error (ER) correct supply voltage

+5V for RS 485

X06 control variable out of Error (ER) control variable > 3mA
range
(current < 3mA)

X07 Irregular TDC-pulses Error (ER) Regular TDC-pulses or 10 seconds

(intermittent signal above after stop
100rpm)

10d Operating hours (hours to Maintenance Do a service on actuators and set

next service) becomes 0 or (MA) new hours or date
the configured date has
been reached

Remarks

 X denotes the number of the SIM (1 to 6).

 Errors X01 to X07 trigger the signal ERROR to the DCS. Compressor control is in an
undefined condition, and error logic has to be implemented in the DCS.

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6.2 Error Table Actuator

Error code Error cause LED and Error reset condition

Output

XY0 failure of an Actuator (no Error (ER) correct data transfer between CIU and
answer from this actuator) actuator

XY1 Hydraulic pressure low (below Phyd Low (HY) Hydraulic pressure above limit
limit)

XY2 Supply voltage for actuators Error (ER) return of supply voltage above 43V
below 39 V

XY3 Not used

XY4 short circuit in solenoid circuit Error (ER) remove short circuit
(monitoring only when (monitoring only when solenoid is triggered)
solenoid is triggered)

XY5 Open circuit in solenoid circuit Error (ER) remove open circuit in electric solenoid
(monitoring only when circuit (monitoring only when solenoid is
solenoid is triggered) triggered)

XY6 failure of temperature sensor Maintenance return to correct function of temperature

(failure in data transfer) (MA) sensor

XY7 Failure of hydraulic pressure Maintenance Return to correct function of hydraulic

sensor (value outside defined (MA) pressure sensor
range)

Remarks
 X denotes the number of the SIM (1 to 6).
 Y standing for the ACT number 1-8
 Errors Y0, Y2, Y4, and Y5 trigger the signal ERROR to the DCS. Compressor control is in an
undefined condition, and error logic has to be implemented in the DCS.

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6.3 Error Correction SIM
6.3.1 Error x.. – No configuration
The configuration is loaded on the CIU by HOERBIGER during
commissioning. As long as no configuration is loaded this error is active.

6.3.2 Error x01 - RS485 Malfunction

In case of a defect of the data transfer to the Actuator the capacity control
system usually interrupts for short periods of time as the Actuator cannot
receive the control signals from the CIU. This error effects all cylinders of
one stage. The ERROR output is cancelled as soon as the error is no
longer active.

Effect on the compressor:

 The delivered gas volume of the stage belonging to the respective
SIM starts varying.
 Switch off the hydraulic unit.
 Control the compressor capacity via bypass.

Checklist:
Repair work may be carried out only by Hoerbiger trained personnel.

 This error usually occurs with a defective data line (cable, plug...)
between the CIU and the actuators.

 Check the cable sockets and connection points on the backplane of the
CIU.
 After shutting down the compressor it is recommended to check the bus
wiring.
 If the bus line is O.K. replace the respective SIM.

6.3.3 Error x02 - Type mismatch

A not allowed combination of field devices is noticed. This error occurs if
actuators are configured in the HSS software one time with Actuator 4 and
another time with Actuator 2 protocol.
Effect on the compressor:
 This error occurs as soon as the power supply is switch on. A
control of this stage is not possible.
 Switch off the hydraulic unit.
 Control the compressor capacity via bypass

Checklist:
Repair work may be carried out only by Hoerbiger trained personnel.

 Replace the wrong field device.

 Is a replacement not possible, the project in the CIU has to be changed.
The configuration has to be a “mixed bus line”, so it’s possible to
operate old and new devices on one bus line. Features of the
HydroCOM 4.1 are not possible.

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6.3.4 Error x03 - Transmission Error RS485
The signals transferred from the Actuators to the SIMs are checked by the
CIU. This error shows that the received signals are not correct. The error
only becomes active after repeated occurrence. The ERROR output is
immediately canceled after the error has been removed, the message
remains until "reset".

Effect on the compressor:

 The HydroCOM system is on zero load.
 Switch off the hydraulic unit
 Compressor control via bypass

Checklist:
Repair work may be carried out only by Hoerbiger trained personnel.

 Check the cable connectors on the rear of the CIU.

 Check, whether the termination (RC-module) has been connected at the
last actuator of the respective bus line.
 Check, that there is no interference or disturbance with other external
electronic devices (mobile phones, radio transmitters,....).
 If necessary replace the respective SIM.
 Check the specification of the HydroCOM buscable.

6.3.5 Error x04 - Invalid Parameters

Occurs if the compressor is started without correct configuration of the CIU
or a new GIM is installed without setting the operating hours.

Effect on the compressor:

 The HydroCOM-system does not operate
 Switch off the hydraulic unit
 Compressor control via bypass.

Checklist:
Repair work may be carried out only by Hoerbiger trained personnel.

 Configure the CIU with the HydroCOM Service Software (refer to HSS
user manual).

During the first preparation of a project the counter of operating hours and
CIU time have to be set, otherwise the error will not reset.

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6.3.6 Error x05 - Low Voltage
A failure in the power supply has occurred. This error should occur with all
SIMs of the CIU.

Effect on the compressor:

 The HydroCOM system is on zero load.
 Switch off the hydraulic unit.
 Control the compressor capacity via bypass.

Checklist:
Repair work may be carried out only by Hoerbiger trained personnel.

 Check whether the power supply (IPS) works correctly. Check supply
voltage and fuse.
 Check the green lights on IPS and GIM
 Replace the GIM resp. the IPS

6.3.7 Error x06 - Invalid Control Variable

The control variable of the DCS is not in the range between 3 and 20mA.

Effect on the compressor:

 The HydroCOM system is on zero load.
 Switch off the hydraulic unit.
 Control the compressor capacity via bypass.

Checklist:
Repair work may be carried out only by Hoerbiger trained personnel.

 Check whether the signal line between the CIU and the DCS is O.K.
Watch out for line break and defective plug-in connections.
 Check correct wiring according to assembly and installation
specification.
 Check the analogue output card of the DCS.
 Disconnect the 3-pole connector belonging to this SIM at the back of the
CIU and measure the current between terminal C+ and C- of the cable
socket. The control signal must be above 3mA.
 If the control signal is correct and the ERROR message is still active
after checking the cable connection the respective SIM has to be
replaced.

6.3.8 Error x07 - TDC Timeout

The plausibility of the TDC-signal is checked in the GIM by assuming that
the speed is above the minimum speed, and the speed cannot change +/-
5% within two revolutions of the crankshaft. Between 100rpm and the
minimum speed is a higher tolerance. If the TDC-pulses are not correct, the
according error message is triggered. The ERROR output is immediately
cancelled with the correct signals or after few seconds if the speed drops
below 100rpm (stop of the compressor).

Note: This error can be triggered during an emergency shut down

(compressor stop with pressured cylinder ends).

Effect on the compressor:

 The HydroCOM system is on zero load.
 Switch off the hydraulic unit
 Compressor control via bypass

Checklist:
Repair work may be carried out only by Hoerbiger trained personnel.

 Check correct installation of the TDC sensor.

 Check wiring of the TDC sensor.
 Check isolation amplifier (LEDs)
 Change TDC sensor and isolation amplifier

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6.3.9 Error 10d – Maintenance reminder

A date or the number of operating hours can be configured in the HSS. The
days up to the next service can be transmitted to the operator via Modbus.
When the date or operating hours are reached, the maintenance signal on
the CIU is activated and the LED indicator lights up. A maintenance
reminder is sent to the operator via binary output or Modbus.

After the service has been carried out, the operating hours counter or the
date of the next service has to be set again.

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6.4 Error Correction Actuator
6.4.1 Error xy0 – Failure of an Actuator
An Actuator with the address y fails at the SIM x.

Effect on the compressor:

 The cylinder end where the failed Actuator is located is on idle
operation. The suction valve is permanent open.
 If the control is not working satisfying, the HydroCOM system has
to be deactivated.
 Switch off the hydraulic unit
 Control the compressor via bypass.

Checklist:
Repair work may be carried out only by Hoerbiger trained personnel.

 This error usually occurs with a defective cable connection in the

Actuator or a defect Actuator.
 Failures of the 48VDC power supply can also lead to this error.

 Check the defective Actuator according to the CIU failure code

 A missing Actuator temperature (-25°C in DCS) can also be an
indication and helpful to detect a defect Actuator.
 Check the connection of the wires in the terminal block of the Actuator.
 Switch Off and On the EPS and CIU to initialize the system (switch on
the EPS first, then the CIU)
 Change the electric housing (take care of the specific bus address and
the termination, refer to “Service Manual chapter 5.2”)

6.4.2 Error xy1 - Hydraulic Pressure Too Low (Errors only possible for systems before 2003)

This signal is only active on installations delivered before 2003. For

applications from 2003 on the pressure sensor installed in the first actuator
will be replaced against a pressure transmitter on the hydraulic unit.
So this monitoring device (error xy1) is not active anymore.

CIU Operating Instructions 4.18.doc 19 2018-07-13

6.4.3 Error xy2 - Supply Voltage below 39 V
This error indicates that the supply voltage of 48VDC at one or more
actuators is not provided or has dropped below 39 VDC.

Effect on the compressor:

 The cylinder end where the failed Actuator is located is on idle
operation. The suction valve is permanent open. The suction valve
temperature rises.
 Switch off the hydraulic unit
 Control the compressor via bypass.

Checklist:
Repair work may be carried out only by Hoerbiger trained personnel.

 Check whether the supply voltage is correct. Check the safety cutout.
Measure the voltage output of the EPS.

 The error can be due to a defective supply line or defective cable

connections.

 Measure the supply voltage at the cable connections in the electric

housing either during operation or simulation. Too low cable cross-
sections result in too high voltage drops.

6.4.4 Error xy4 - Short Circuit in Solenoid Circuit

The self-test of the CIU has discovered that the solenoid in this IVD shows
too low resistance. The actuator concerned is automatically switched off
and this error message is triggered.

Effect on the compressor:

 The cylinder end where the failed Actuator is located is on idle
operation. The suction valve is permanent open. The suction valve
temperature rises.
 Switch off the hydraulic unit
 Compressor control via bypass

Checklist:
Repair work may be carried out only by Hoerbiger trained personnel.

 Replace the respective valve housing.

CIU Operating Instructions 4.18.doc 20 2018-07-13

6.4.5 Error xy5 - Line Break in the Solenoid Circuit
The self test of the CIU has discovered that the solenoid in this IVD shows
too high resistance. The actuator concerned is automatically switched off
and this error message is triggered.

Effect on the compressor:

 The cylinder end where the failed Actuator is located is on idle
operation. The suction valve is permanent open. The suction valve
temperature rises.
 Switch off the hydraulic unit
 Compressor control via bypass

Checklist:
Repair work may be carried out only by Hoerbiger trained personnel.

 Replace the respective valve housing.

6.4.6 Error xy6 - Failure Temperature Sensor

The self test of the CIU has discovered that the temperature sensor is
defective. The measured values are out of the defined range. This error
triggers Maintenance to the DCS. The error is canceled as soon as the
sensor works properly.

This error occurs when actuators are removed and installed without
switching off the power supplies of EPS and CIU.

Effect on the compressor:

 The temperature values reported by this Actuator are incorrect.
 No further effect on the operation of the compressor.

Checklist:
Repair work may be carried out only by Hoerbiger trained personnel.

 Check if socket and plug between seal housing and valve housing are
not damaged.
 Check if there is corrosion/dirt on the socket of on the plug
 Change seal housing
 Change valve housing

6.4.7 Error xy7 - Failure Hydraulic Pressure Sensor

This signal is only active on installations delivered before 2003. For
applications from 2003 on the pressure sensor installed in the first actuator
will be replaced against a pressure transmitter on the hydraulic unit.
So this monitoring device (error x7) is not active in the actuator (IVD)
anymore.

CIU Operating Instructions 4.18.doc 21 2018-07-13

7 MODBUS Communication
The following chapter 7.1 “Definition of MODBUS Protocol” contains general
information of MODBUS and about its parameters.
The chapter 7.2 “Parameters and Registers of HydroCOM 4.1” is important
for configuration of the devices in the MODBUS network and the application
specific programming.
The chapter 7.3 “Configuration of MODBUS connections” contains
information of the MODBUS connection.
The chapter 7.4 “Programming of a MODBUS Master” shows examples for
generating a master in programming-language C.

This information of following chapters is relevant to programmers of the

MODBUS master and not necessarily for end-users.

For reference of MODBUS see:

Modicon MODBUS Protocol Reference Guide
PI-MBUS-300 Rev. J
available from SCHNEIDER AUTOMATION

7.1 Definition of the MODBUS protocol

The MODBUS protocol allows communication of 1 master (e.g. DCS / PLC)
with up to 247 slaves (e.g. CIU). Each slave has a fixed address (1-247).
Only the master initiates a transaction. The transaction (serial transmission)
can be a “query - response cycle” or a “broadcast/no response operation”.

Sketch:

MODBUS Master
e.g. DCS / PLC

MODBUS Network

Slave 1
e.g. CIU Slave 2 Slave n

Several characteristics can be defined by the user. These parameters

must be defined at each station, and cannot be changed during a
session.
Remark: The CIU must be switched off and on, to recognize any
changes of these parameters

ID – Address
Transmission medium (RS232 or RS485)
Baud-rate
Parity
Number of Stop-Bits
Transmission mode (ASCII or RTU)

The master can send a new message as soon as the slave has responded
or after a defined delay has passed. In broadcast-mode only messages can
be sent which do not trigger a response.

CIU Operating Instructions 4.18.doc 22 2018-07-13

7.1.1 ID - Address
Each device in the MODBUS network (master and slaves) must have a
unique address. If there are two devices with the address the
communication will be influenced and cannot work correct.

7.1.2 Transmission Medium

There are two media of transmission possible: RS 232 and RS485. One
mode has to be selected in MODBUS network, depending on the
application. Only with special converters it is possible to mix this two
transmission mediums.

Characteristics RS 232 RS 485

Working principle Transmission of voltage with Transmission of differential
reference on a common ground level. voltage
Number of wires cable with Sub D9 Plugs 2 or 4 (for CIU only 2 wires)
Maximum Distance 10m 1000m
Multi – Slave network not possible possible

7.1.3 Baud-Rate
The Baud-rate equals to the sum of data-bits and control bits per seconds.
According the Modicon MODBUS Protocol Reference Guide a lot of
different Baud-rates are theoretical possible, but only few are usual (cf.
7.2.1)

7.1.4 Parity
The configuration of the parity bit sets the devices to use this control bit or
not.

7.1.5 Stop-Bit
The configuration of the stop bit sets the devices to use this control bit or
not. The number of stop-bits depends on the parity bit.

7.1.6 Transmission Mode

There are two modes of transmission possible, both offer the same
possibilities. One mode has to be selected, mixing of modes is not
permitted.

Characteristics ASCII (7-bit) RTU (8-bit)

Coding system hexadecimal (ASCII-characters 8-bit
0-9, A-F)
Number of bits per character 9 or 10 10 or 11
Start bit 1 1
Data bits (LSB first) 7 8
Parity (optional) 1 (for even/odd parity 1 Bit is sent, for no 1 (for even/odd parity 1 Bit is sent,
parity no bit) for no parity no bit)
Stop bit 1 or 2 1 or 2
Error check LRC (Longitudinal Redundancy CRC (Cyclical Redundancy
Check) Check)

ASCII-characters can easily be visualized and are used for debugging. In

RTU-mode (Remote Terminal Unit) 8 bit binary characters are sent.
In ASCII-mode each RTU character is split into two ASCII-characters. That
means that the double data amount has to be transmitted in ASCII-mode.
In RTU-mode data has to be transmitted in a continuous data flow (time-out
3.5 characters), in ASCII-Mode intervals of up to 1 second are permitted.

CIU Operating Instructions 4.18.doc 23 2018-07-13

7.1.7 Error detection
If a character framing, parity or redundancy check error is detected, the
slave does not respond any longer (result similar to wrong address). The
master must be implemented in a way that this can be recognized.

After a certain time the message is automatically resent by the master.

Details and examples for implementation in C confer chapter 7.4.3

7.1.8 Data and Control Functions

With the function code the basic address is already defined, only the offsets
are transmitted in the MODBUS-message.

Diverse information can be transmitted:

status register (1 bit, Input Status .. read only, Output Status .. read/write)
register (16 bit, Input Register .. read only, Output Register .. read/write)
status registers can be combined (Coils 8 Bit), for optimum transmission.

Marked functions can be used for communication to the CIU.

Overview:

Address range Base address Code remark

0000 1999 1 01 Read Output Status
05 Force Single Coil
15 Force Multiple Coils

10000 19999 10001 02 Read Input Status

30000 39999 30001 04 Read Input Register

40000 49999 40001 03 Read Holding Register

06 Write Single Register
16 Write Multiple Register

General functions:

Code Broadcast Name Remark

01 no Read Output Status
02 no Read Input Status
03 no Read Holding Register Read
04 no Read Input Register Read
05 yes Force Single Coil
06 yes Preset Single Register Write
07 no Read Exception Status
Only for CIU2.0 08 no Loopback Test Diagnostic function

15 yes Force Multiple Coils

16 yes Preset Multiple Register Write

CIU Operating Instructions 4.18.doc 24 2018-07-13

7.1.9 Exception Response
If a Master sends a query to a Slave, there are four cases (Broadcast
excepted):
 The Slave receives the query without communication error and can
handle it normally. The slave returns a normal response.

 The Slave receives the query with communication error (e.g..: query not
complete), then no response is returned. The master program will
generate a Time-out for this query.

 The Slave receives the query completely, but a communication error is

recognized (parity, LRC or CRC), then no response is returned. The
master program will generate a Time-out for this query.

 The Slave receives the query without communication error, but the
query cannot be handled (e.g.: read a non-existing register). The slave
returns an exception response. The master is informed about the error.

The exception response differs from a normal response as follows:

7.1.9.1 Function Code Field

In a normal response the slave echoes the original query code. All function
codes are below 80H.
With the error response the MSB of the query code is set and returned.
The Master can thus distinguish between a normal response and an error
response.

7.1.9.2 Data field

In a normal response data or statistical information is transmitted in the data
field. In the error response an error code is transmitted.

Error codes:
ode Name Meaning
01 ILLEGAL FUNCTION The Command is not supported by the Slave.
02 ILLEGAL DATA ADDRESS Data addresses are not supported.
03 ILLEGAL DATA VALUE A value is not admissible.
04 SLAVE DEVICE FAILURE An error is detected while the query is
processed.
05 ACKNOWLEDGE The query is accepted and handled. However
handling takes so long that a master time-out
might occur. Therefore the Master is informed
with this error code.
06 SLAVE DEVICE BUSY The Slave is busy with a duty taking much time.
The Master shall inquire later again.
07 NEGATIVE ACKNOWLEDGE The Slave cannot carry out the program task.
08 MEMORY PARITY ERROR A memory error is detected.

CIU Operating Instructions 4.18.doc 25 2018-07-13

7.2 Parameters and Registers of HydroCOM 4.1
7.2.1 General Specification - Parameters

Characteristics MODBUS (general) MODBUS-Interface (GIM)

Transmission mode 7-Bit ASCII with LRC Error-Check 7-Bit ASCII with LRC Error-Check
or 8-Bit Binary (RTU) with CRC or RTU (8-Bit Binary) with CRC
Error-Check. Error-Check.
Parity Bits even, odd or none even, odd or none
Stop Bits 1 or 2 1 or 2
Baudrate 50, 75, 110, 134.5, 150, 300, 600, 1200, 2400, 4800, 9600, 19200,
1200, 1800, 2000, 2400, 3600, 4800, 38400
7200, 9600 or 19200
Device Mode Master or Slave Slave
Query Function Codes 1-8, 11-17 3, 4, 6, 8, 16 and 65
Loopback Diagnostic 0-4, 10-18 0-4, 10-16 only for CIU 2.0
Maximum Coils in 2000 none
"READ STATUS"
Maximum Registers in 125 125
"READ REGISTER"
Exception Response 1-7 1,2,3
Codes
Broadcast Mode yes no
Device Address 1-247 1-247
Timeout ASCII 1sec ASCII 1sec
RTU 3.5 characters RTU 3.5 characters
Protocol repetition with Master (continuous) Master (continuous)
Error Slave (after Master query) Slave (after Master query)

Remark: All parameters must be identical with those

of the MODBUS master! The CIU must be
switched off and on, to recognize any
changes of MODBUS parameters.
The following functions are implemented:

Code Name Remark

03 Read Holding Register Read load and control signals, registers 4XXXX
04 Read Input Register Measured values and profiles from Actuators, registers 3XXXX
06 Preset Single Register Write load and control signals to CIU, register 4XXXX
08 Diagnostics Diagnostic function only for CIU 2.0
16 Preset Multiple Register Write data to a consecutive number of registers 4XXXX
65 HSS connection, for future use

CIU Operating Instructions 4.18.doc 26 2018-07-13

 The following sub-functions are supported for diagnostic only for CIU 2.0:

Code Name Remark GIM

00 Return Query Data Echo function y
01 Restart Comm Option carry out Reset y
02 Return Diagnostic several error flags (EPROM-error, y
Register Timer error, a.s.o.)
03 Change ASCII Input Default LF can be replaced. y
Delimiter
04 Force Listen Only The Slave does not answer any longer y
Mode (Reset with Sub Code 01)
05-09 Reserved
10 Clear Ctrs and Diagno- Counters are cleared y
stic Reg.
11 Return Bus Message Number of received protocols (without y
Count CRC/LRC errors)
12 Return Bus Comm. Number of transmission errors (only y
Error Count CRC/LRC error)
13 Return Bus Exception y
Error Count
14 Return Slave Message Number of slave-adressings (without y
Count error)
15 Return Slave No Re- Number of slave-adressings, which y
sponse Count were not answered
16 Return Slave NAK Number of slave-adressings, which y
Count were answered by Exception (NAK).
17 Return Slave Busy n
Count
18 Return Bus Char. Over- n
run Count
19 Return Overrun Error n
Count
20 Clear Overrun Counter n
and Flags
21 Get/Clear MODBUS n
Plus Statistics
22- Reserved

CIU Operating Instructions 4.18.doc 27 2018-07-13

7.2.2 Data Registers
7.2.2.1 Read Only Registers (Input Registers)

Information is read with function 04 (Read Input Register).

Addresses 30001 to 39999 (Base address 30001) are used for this
command.

7.2.2.1.1 CIU Status

Flags are packed into a 16-Bit register:
; HydroCOM Info
; d00 .. Hydraulic pressure low (1-active)
; d01 .. Error HydroCOM (1-active)
; d02 .. Maintenance HydroCOM (1-active)
; d03 .. Spare
; d04 .. Spare
; d05 .. Power failure 15V (1-active)
; d06 .. Power failure 5V (1-active)
; d07 .. Speed under Min.speed (1-active)
; d08 .. failure SIM 1 (1-active)
; d09 .. failure SIM 2 (1-active)
; d10 .. failure SIM 3 (1-active)
; d11 .. failure SIM 4 (1-active)
; d12 .. failure SIM 5 (1-active)
; d13 .. failure SIM 6 (1-active)
; d14 .. Spare
; d15 .. failure SIM (collective message)(1-active)

30001
CIU Status

7.2.2.1.2 Actual Binary Inputs (hardwired or MODBUS-controlled)

The actually acting binary inputs of the CIU are stored in the following
register, as well as the hardware inputs.
; Digital IO's
; d00 .. Enable actual status (1-active)
; d01 .. Simulation actual status (1-active)
; d02 .. Enable status (HW-input) (1-active)
; d03 .. Simulation status (HW-input) (1-active)
; d04 - d15 .. Spare

30002
IO

7.2.2.1.3 Actual Control variables (hardwired or MODBUS-controlled)

The actually acting control variables are stored in the following registers:

30003 30004 30005 30006 30007 30008

Y1 Y2 Y3 Y4 Y5 Y6

These registers store the 4..20mA signal if the hard-wired control mode is
configured. Otherwise, in the MODBUS control mode, values of the
registers 40001 to 40006 are copied.

The format of the registers is the same as described in section 7.2.2.2.1.

CIU Operating Instructions 4.18.doc 28 2018-07-13

7.2.2.1.4 Actual Speed
This register contains the 12bit integer value RPM (LSB = 1RPM). The
theoretical range is from 0 to 4095 RPM.
; Speed
; d00 – d11 .. binary value of actual speed in RPM
; d12 - d15 .. Spare

30009
Speed

7.2.2.1.5 Operating Hours

There are two 32bit counters for operating hours, one for engine hours and
one for HydroCOM control hours. Both have resolution of 1 hour and are
stored in double integer format (two 16bit words, lower significant word
first).

Engine hours: counts full hours, when compressor runs above 100 RPM.

30010 30011
CTR1 Low CTR1 High

HydroCOM control hours: counts full hours, when compressor runs above
100 RPM and signal ENABLE is set.

30012 30013
CTR2 Low CTR2 High

7.2.2.1.6 Days to next service (=Maintenance)

This value will be displayed as decimal number from 0-4094.

A value of 4095 indicates that no service has been set.

30014
Days to next service

CIU Operating Instructions 4.18.doc 29 2018-07-13

7.2.2.1.7 SIM Status
Flags are packed into two 16-bit registers per SIM:
; SIM-Error
; d00 .. RS485 bus defect (error, bus conflict or
short circuit) (1-active)
; d01 .. Spare
; d02 .. RS485 transmission error (1-active)
; d03 .. Parameters not valid (1-active)
; d04 .. low voltage 15V or +5V RS485(1-active)
; d05 .. control variable UnderRange (1-active)
; d06 .. TDC Error(1-active)
; d07 .. Type Mismatch
; d08 - d14 Spare
; d15 .. SIM existing (1..existing, 0..not
existing or not projected)

; failure Actuator
; d00 .. failure ACT1 (1- active)
; d01 .. failure ACT2 (1- active)
; d02 .. failure ACT3 (1- active)
; d03 .. failure ACT4 (1- active)
; d04 .. failure ACT5 (1- active)
; d05 .. failure ACT6 (1- active)
; d06 .. failure ACT7 (1- active)
; d07 .. failure ACT8 (1- active)
; d11-d15 Spare

Not projected SIMs show 0x0000.

30022 30023
SIM1 SIM-Error Failure ACT
30024 30025
SIM2 SIM-Error Failure ACT
30026 30027
SIM3 SIM-Error Failure ACT
30028 30029
SIM4 SIM-Error Failure ACT
30030 30031
SIM5 SIM-Error Failure ACT
30032 30033
SIM6 SIM-Error Failure ACT

CIU Operating Instructions 4.18.doc 30 2018-07-13

7.2.2.1.8 Actuator Status
Flags are packed into one 16-bit register per Actuator:
ACTx
; d00 .. low voltage 48V (1-active)
; d01 .. solenoid short circuit (1-active)
; d02 .. solenoid open circuit (1-active)
; d03 .. Spare
; d04 .. failure temperature sensor (1-active)
; d05 .. Hydraulic pressure low
; d06 .. solenoid active (1-active)
; d07 .. Spare

; d08 .. failure hydraulic sensor (1-active)

; d09 .. ActiValve control(only for Act-4)(1-act.)
; d10 .. Measured value scaling over full
temperature range (-55°C…+125°C)
; d11 .. No temperature sensor installed
- Measured value invalid
; d12 .. Spare
; d13 .. Hydraulic sensor configured
; d14 .. Actuator-4 projected (1-active)
; d15 .. Actuator projected (1..existing,
0..not existing)

30034 30035 30036 30037 30038 30039 30040 30041

SIM1 ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACT7 ACT8
30042 30043 30044 30045 30046 30047 30048 30049
SIM2 ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACT7 ACT8
30050 30051 30052 30053 30054 30055 30056 30057
SIM3 ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACT7 ACT8
30058 30059 30060 30061 30062 30063 30064 30065
SIM4 ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACT7 ACT8
30066 30067 30068 30069 30070 30071 30072 30073
SIM5 ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACT7 ACT8
30074 30075 30076 30077 30078 30079 30080 30081
SIM6 ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACT7 ACT8

Not projected Actuators show 0000h.

7.2.2.1.9 Temperature Values Actuator

The used range of temperature values is between –25° and +125°C or
-55°C and +125°C; assignment is as follows:

Measuring value analog Out hexadezimal decimal

–25°C / -55°C 4mA 0x0000 0
+125°C 20mA 0x0FFF 4095

30626 30627 30628 30629 30630 30631 30632 30633

SIM1 ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACT7 ACT8
30634 30635 30636 30637 30638 30639 30640 30641
SIM2 ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACT7 ACT8
30642 30643 30644 30645 30646 30647 30648 30649
SIM3 ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACT7 ACT8
30650 30651 30652 30653 30654 30655 30656 30657
SIM4 ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACT7 ACT8
30658 30659 30660 30661 30662 30663 30664 30665
SIM5 ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACT7 ACT8
30666 30667 30668 30669 30670 30671 30672 30673
SIM6 ACT1 ACT2 ACT3 ACT4 ACT5 ACT6 ACT7 ACT8

Not projected Actuators will contain 0x0000.

CIU Operating Instructions 4.18.doc 31 2018-07-13

7.2.2.1.10 Message Memory SIM
For each SIM 64 messages can be stored. One message is contained in
one 16-bit register. The message consists of error type and device-number
corresponding to the middle and right digit of the display at the SIM.
; Message
; d00 - d03 .. error type
; d04 - d07 .. device address (0 through B)
; d08 - d15 .. spare

31500 31501 31563

SIM1 message 1 message 2 .. message 64
31564 30565 30627
SIM2 message 1 message 2 .. message 64
30628 30629 30691
SIM3 message 1 message 2 .. message 64
30692 30693 30755
SIM4 message 1 message 2 .. message 64
30756 30757 30819
SIM5 message 1 message 2 .. message 64
31820 30821 30883
SIM6 message 1 message 2 .. message 64

CIU Operating Instructions 4.18.doc 32 2018-07-13

7.2.2.2 Read / Write Registers (Holding Registers)
Information is read with function 03 (Read Holding Register) and written
with function 06 or 16.
Addresses 40001 to 49999 (Base address 40001) are used for these
commands.

7.2.2.2.1 Control variable (SIM1 through SIM6)

The range of values is from 0 to 4095, the assignment is as follows:

MODBUS Hardwired Display HSS SOLon

- 0 mA ...% 360 °CA
- >3 mA 0.0 % 360°CA
0 4,0 mA 0.0 % 360°CA
4095 20,0 mA 100.0 % 140°CA
- >20 mA 100.0 % 140°CA

40001 40002 40003 40004 40005 40006

Y1 Y2 Y3 Y4 Y5 Y6

The actual control variable acting onto the actuators (independently whether
MODBUS-controlled or hard-wired) is stored in registers 30003 to 30008.
(cf. section 7.2.2.1.3).

7.2.2.2.2 Digital Inputs (GIM)

Remark: The function 03 and function 06 or 16 read / write always an
integer value from / to the register, so the binary information has to be
evaluated from this integer value (cf. section 7.3.1)

The Flags are packed in two 16-bit registers:

; Digital IO's
; d00 .. Enable control variable (1-active)
; d01 .. External Simulation (1-active)
; d02 – d15 .. Spare

Function 03 does not read the hardware inputs but the MODBUS-flags.
Actual binary signals (regardless which control mode is configured) can be
read out from register 30002 (cf. section 7.2.2.1.2).

40007
IO

; Digital IO's
; d00 .. Clear error report SIM 1 (1-active)
; d01 .. Clear error report SIM 2 (1-active)
; d02 .. Clear error report SIM 3 (1-active)
; d03 .. Clear error report SIM 4 (1-active)
; d04 .. Clear error report SIM 5 (1-active)
; d05 .. Clear error report SIM 6 (1-active)
; d06 – d15 .. Spare

The reset command is available in both, MODBUS - controlled and hard-

wired control.

40008
IO

CIU Operating Instructions 4.18.doc 33 2018-07-13

7.2.2.2.3 Free addressable Write Registers
The CIU allows to store values in registers 40009 to 40056 which can be
connected to analogue 4..20mA outputs of the SIMs.

Text Analog Out hexadezimal dezimal

Begin range 4mA 0x0000 0
End range 20mA 0x0FFF 4095

40009 40010 40011 40012 40013 40014

value 1 value 2 value 3 value 4 value 5 value 6
40015 40016 40017 40018 40019 40020
value 7 value 8 value 9 value 10 value 11 value 12
40021 40022 40023 40024 40025 40026
value 13 value 14 value 15 value 16 value 17 value 18
40027 40028 40029 40030 40031 40032
value 19 value 20 value 21 value 22 value 23 value 24
40033 40034 40035 40036 40037 40038
value 25 value 26 value 27 value 28 value 29 value 30
40039 40040 40041 40042 40043 40044
value 31 value 32 value 33 value 34 value 35 value 36
40045 40046 40047 40048 40049 40050
value 37 value 38 value 39 value 40 value 41 value 42
40050 40052 40053 40054 40055 40056
value 43 value 44 value 45 value 46 value 47 value 48

CIU Operating Instructions 4.18.doc 34 2018-07-13

7.3 Configuration of MODBUS connections
The MODBUS connections (9-pole Sub-D pin connectors on the backplane
of the CIU) can be configured by the HSS software as RS232 (for single
point communication) or RS485 interface (for multipoint).
Pins 2, 3, and 5 are connected to screw terminals as well. They must not be
used, when the Sub-D connector is used.

Note: For RS232 connection use a null-modem cable (pins 2 and 3

are crossed)

Pin no. RS232 RS485

1,9 not used
2 RXD A+
3 TXD B.
4,6 bridged
5 ground (insulated)
7,8 bridged

Fig.6: MODBUS interfaces and binary I/O

CIU Operating Instructions 4.18.doc 35 2018-07-13

7.4 Programming of a MODBUS Master
7.4.1 Evaluation of Register Information
The MODBUS functions 03, 04 (read) and 06 (write) can only read and write
complete registers. In this registers are 16-bit integer values, range from 0
to 32768.

7.4.1.1 Example: Register 30001

Output: 129
During stopped compressor and stopped Hydraulic Unit the value of the
register 30001 is 129, so this integer value has to be converted into a 16-bit
binary value.

The decimal value (129) gives a binary value (10000001). Then this binary
value has to be filled up into a 16-bit binary format:
7 0
129 = 12 + 12 = 1 0 0 0 0 0 0 1

15 7 6 5 4 3 2 1 0
2 ... 2 2 2 2 2 2 2 2
 fill up:
0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1

d15 d14 d13 d12 d11 d10 d09 d08 d07 d06 d05 d04 d03 d02 d01 d00

 refer list of binary information in section 7.2.2.1.1 :

d01 = 1 … Hydraulic pressure low
d07 = 1 … Speed under minimum
rest = 0 … no more failures

 HydroCOM Info: CIU on, HU not running, Compressor not running, no

enable set

 Status: Okay, ready for operation

Output: 387

387 = 110000011

 fill up:
0 0 0 0 0 0 0 1 1 0 0 0 0 0 1 1

d15 d14 d13 d12 d11 d10 d09 d08 d07 d06 d05 d04 d03 d02 d01 d00

 refer list of binary information in section 7.2.2.1.1:

d00 = 1 … Hydraulic pressure low
d01 = 1 … Error HydroCOM
d08 = 1 … Speed under minimum
d09 = 1 … failure SIM 1
rest = 0 … no more failures

 CIU on, HU not running, Compressor not running, no enable set, failure
at SIM 1

 Status: Error, not ready for operation, refer to register 30022 and 30023
for a detailed failure analyse.

CIU Operating Instructions 4.18.doc 36 2018-07-13

7.4.1.2 Example: Register 30626
Output: 2000
The used range of temperature values is between –25° and +125°C
(correspond to 0…4095; cf. section 7.2.2.1.10) , so the output has to be
scaled.

0 … -25°C
4095 … 125°C
2000 … ? °C  linear equation: y=kx+d

x … y

0 … -25°C  -25 = k  0 + d
4095 … 125°C  125 = k  4095 + d
 d = -25
 125 = k  4095 - 25
 k = 0,03663

 temperature = 0,03663  raw value - 25

t2000 = 48.3°C

CIU Operating Instructions 4.18.doc 37 2018-07-13

7.4.2 Functions (examples)
7.4.2.1 04 Read Input Register

Description
The Maintenance and the Error outputs of HydroCOM 4.1 shall be called
up. Broadcast is not possible.

Query

It shall be checked, whether an error or Maintenance has occurred at

HydroCOM 4.1. The protocol example reads address 30001 from the slave.

Query

Field name example

(Hex)

Slave Address 11
Function 04
Offset HI 00
Offset LO 00
Number of points HI 00
Number of points LO 01
Check sum ..
(CRC or LRC)

Response

The register (16 bit) is packed into the response data field (2 Bytes).

State:
1 ON output active (LED on)
0 OFF output inactive (LED off)

The Byte counter indicates how many Bytes are sent.

As d00 (Maintenance) is ON and d01 (Error) is ON, both outputs are active
and both LEDs are switched on.

Response

Field name example

(Hex)

Slave Address 11
Function 04
Byte counter 02
Data HI (Register 30001) 00
Data LO (Register 30001) 03
Check sum ..
(CRC or LRC)

CIU Operating Instructions 4.18.doc 38 2018-07-13

7.4.2.2 08 Diagnostic function only for CIU 2.0

Description
The MODBUS function 08 supports a number of test routines in order to
detect internal failures of the slave. Broadcast is not possible.

The function uses a two-byte subfunction. The slave echoes slave address,
function code and subfunction.

Query

The echo function shall be used.

Query

Field name example (Hex)

Slave Address 11
Function 08
Subfunction HI 00
Subfunction LO 00
Data HI A5
Data LO 37
Check sum ..
(CRC or LRC)

Response

The complete query string is returned.

Response

Field name example (Hex)

Slave Address 11
Function 08
Subfunction HI 00
Subfunction LO 00
Data HI A5
Data LO 37
Check sum ..
(CRC or LRC)

CIU Operating Instructions 4.18.doc 39 2018-07-13

7.4.3 Error detection
If a character framing, parity or redundancy check error is detected, the
slave does not respond any longer (result like with wrong address). The
master must be implemented in a way that this can be reckoned.

After a certain ast-TIMe the message is automatically resent by the master.

In the RTU-mode the CRC error detection code is used and in the ASCII-
mode the LRC-check (Longitudinal Redundancy Check) is used.

7.4.3.1 CRC
(RTU-mode)

In order to define the CRC code the following steps must be taken.

1. Load a 16-bit register with FFFF hex (all 1’s).

2. Exclusive OR the first 8-bit byte of the message with the low-order byte of the 16-
bit register. The result should again be filed in the 16-bit register.

3. Shift 16-bit register 1 bit to the right

4a. If the bit shifted out is a 1, exclusive-or the register with 1010 0000 0000 0001.

4b. If the bit shifted out is a 0, repeat step 3.

5. Repeat steps 3 and 4,until 8 shifts are accomplished.

6. Exclusive OR the next 8-bits of the message with the low-order byte of the 16-bit
register. The result should again be filed in the 16-bit register.

7. Repeat steps 3 to 6 until all data have been processed.

8. The contents of the 16-bit register is the 2-byte CRC code and is added to the
message with the low-order byte at first place.

Implementation (in C):

/* File rtu_crc1.c */
#include <stdio.h>
unsigned int msg[] = {0x02, 0x07 };
unsigned int msg_len = 2;
unsigned int crc;

void main()
{
int i,ii;

crc = ~0;

for (i=0; i<msg_len; i++)

{
crc ^= msg[i];
for (ii=0; ii<8; ii++)
if ( (crc&0x01)!=0)
{
crc >>= 1;
crc ^= 0xA001;
}
else
{
crc >>= 1;
}
}
printf("%x \n",crc);

} /* main() */

CIU Operating Instructions 4.18.doc 40 2018-07-13

7.4.3.2 LRC
(ASCII-mode)

The LRC-check (Longitudinal Redundancy Check) is used in the ASCII-

mode, the 8 bit Error check is transmitted as two ASCII characters.

The accumulated sum of all data is made. ´:´, CR and LF are not used for
calculation..

Implementation (in C):

/* File asc_lrc1.c */

#include <stdio.h>

unsigned int msg[] = {0x02, 0x01, 0x00, 0x00, 0x00, 0x08 };

unsigned int msg_len = 6;

unsigned int lrc;

void main()
{
int i;

lrc = 0;

for (i=0; i<msg_len; i++)

lrc += msg[i];
lrc = (~lrc)+1;
printf("%x \n",lrc);

} /* main() */

Practical test:

Example 1 (ASCII):
The following string was received by the automation software LOOKOUT:
:010300000001FB
It could be reproduced with test program asc_lrc2.c (msg[] = {0x01, 0x03,
0x00, 0x00, 0x00, 0x01 }) of LRC 0xFB.

Example 2 (ASCII):
The following string was received by the automation software LOOKOUT:
:050400010001F5

Example 3 (RTU):
The following string was received by the automation software LOOKOUT:
0x05, 0x04, 0x00, 0x01, 0x00, 0x01, 0x61, 0x8E

CIU Operating Instructions 4.18.doc 41 2018-07-13