INSTRUCTIONS

MODBUS TCP CARD

RIGHT FROM
THE START

Contents
1. Introduction ......................................................................................... 3
2. Installation ........................................................................................... 4
3. Device configuration ............................................................................ 5
4. PLC configuration.............................................................................. 11
5. Ground fault protection ..................................................................... 11
6. Operation ........................................................................................... 12
7. Modbus registers .............................................................................. 13
8. Network design ................................................................................. 22
9. Specifications .................................................................................... 24

Compatibility
This manual is suitable for:
• Modbus TCP Card
• Modbus TCP Card with Ground Fault

These cards are suitable for use with EMX4e and EMX4i soft starters.
The available features may vary according to the model and version of the starter.

This user manual is intended for use with version 2.x of the Modbus TCP Card. Version
1.x of the Modbus TCP Card does not support custom users or IoT operation.

© 2021 AuCom Electronics Ltd. All Rights Reserved.

Modbus TCP Card | Rev C 5/2021

INSTRUCTIONS

Disclaimer
The examples and diagrams in this manual are included solely for illustrative
purposes. The information contained in this manual is subject to change at any time
and without prior notice. In no event will responsibility or liability be accepted for
direct, indirect or consequential damages resulting from the use or application of this
equipment.
Failure to follow the information and instructions in this manual will void the warranty.

Warnings
It is the installer's responsibility to follow all instructions in this manual and to follow
correct electrical practice.

WARNING
For your safety, isolate the soft starter completely from mains voltage before
attaching or removing accessories.
WARNING
Inserting foreign objects or touching the inside of the starter while the
expansion port cover is open may endanger personnel, and can damage the
starter.

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1. Introduction
1.1 Product design
The Modbus TCP Card allows the soft starter to connect to an Ethernet network and be
controlled or monitored using an Ethernet communication model.

Familiarity with Ethernet protocols and networks is required to operate the device
successfully. For difficulties using this device with third party products, including
PLCs, scanners and commissioning tools, contact the relevant supplier.

1.2 Connections
1 2 3

23081.A
1 2 x RJ45 ethernet ports, supporting line, star, ring and loop network topologies
2 2 pin connector for ground fault CT (selected models)
3 DB9 connector for optional remote keypad

1.3 Communication protocols

The Modbus TCP Card supports the following protocols:
Modbus TCP Industrial ethernet via Modbus TCP
MQTT Message Queue Telemetry Transport
OPC UA Open Platform Communications Unified Architecture
2 3

4
22542.A

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1 Soft starter
2 Network switch
3 IoT connection (MQTT/OPC UA)
4 Industrial ethernet connection to programmable logic controller

2. Installation
2.1 Installing the expansion card
1. Push a small flat-bladed screwdriver into the slot in the centre of the expansion
port cover, and ease the cover away from the starter.
2. Line up the card with the expansion port. Gently push the card along the guide rails
until it clicks into the starter.
1 2

B4 B5 1011 12 13 B4 B5 1011 12 13
14 15 21 22 14 15 21 22
33 34 41 42 44 53 33 34 41 42 44 53
54 54

17049.A

2.2 Network connection

Ethernet ports
The device has two Ethernet ports. If only one connection is required, either port can
be used.

Cables
Use Category 5, 5e, 6 or 6e cable to connect to the device.

EMC precautions
To minimise electromagnetic interference, Ethernet cables should be separated from
motor and mains cables by 200 mm.
If the Ethernet cable must cross motor or mains cables, the crossing should be at an
angle of 90°.

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2.3 Network establishment

The controller must establish communications directly with each device before the
device can participate in the network.

2.4 Addressing
Each device in a network is addressed using a MAC address and an IP address.
• The device can be assigned a static IP address during configuration, or can be
configured to accept a dynamic IP address (via DHCP).
• The MAC address is fixed within the device and is printed on a label on the front of
the device.

3. Device configuration
NOTE
The Error LED flashes whenever the device is receiving power but is not
connected to a network. The Error LED will flash occasionally during the
configuration process.
NOTE
At power-up, the card loads the IP address stored in the soft starter.

3.1 Configuration methods

Network communication parameters for the card can be set via the soft starter or via
the on-board web server.
• The card uses a static IP address by default. To enable DHCP addressing, set
parameter 12T DHCP to ‘Enable’ or change the setting via the on-board web server.
• The IP address can be configured via the soft starter's programmable parameters.
• The web server can configure the IP address and messaging settings for MQTT or
OPC UA operation.

3.2 Configure network settings via the starter

Use parameters 12H~12U to configure the network address.
Parameter Parameter name Default
12H Gateway Address 192
12I Gateway Address 2 168
12J Gateway Address 3 0
12K Gateway Address 4 100
12L IP Address 192
12M IP Address 2 168
12N IP Address 3 0
12O IP Address 4 2

Modbus TCP Card (710-16501-00C) 5

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Parameter Parameter name Default

12P Subnet Mask 255
12Q Subnet Mask 2 255
12R Subnet Mask 3 255
12S Subnet Mask 4 0
12T DHCP Disable
12U Location ID 0

3.3 Enabling network control

The soft starter will only accept commands from the Modbus TCP Card if parameter
1A Command Source is set to 'Network'.

NOTE
If the reset input is active, the starter will not operate. If a reset switch is not
required, use parameter 7I to set the reset input to normally open or fit a link
across terminals 10, 11 on the soft starter.

3.4 On-board web server

Connect to the device
To configure settings using the on-board web server, the card must be installed in a
soft starter, control power must be available, and the card and computer must both be
connected to the Ethernet network.

The computer must use a fixed IP address (not DHCP) and the same subnet mask as
the card. The default IP address for the card is 192.168.0.2. The default subnet mask is
255.255.255.0.

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Once connected, the web server reports basic information about the card and the soft
starter.

Manage users and passwords

NOTE
For security reasons, we recommend that you define a custom administrator
ID and password.
The default username and password are:
username: admin
password: 1978
NOTE
Version 1.x of the Modbus TCP Card does not support custom users.
The Modbus TCP Card supports multiple users and levels of privilege.
• Users can view the home screen and IP address settings
• Supervisors can view the home screen and IP settings and can change
configuration settings
• Administrators can view the home screen, change configuration settings and add or
delete users
To add a new user:
1. Connect to the web server then click Administration.
2. Click Create new user.
3. Enter the new username and password then click Create an account.
4. Set privileges (user, supervisor, administrator) as appropriate.
5. Click Save changes.

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To delete a user:
1. Connect to the web server then click Administration.
2. Click the required entry in the user list then click Delete user. Click Delete again to
confirm the action.

Configure the IP address

For version 1.x of the Modbus TCP Card, changes made via the web server are
not stored in the soft starter and will be lost when control power is cycled.
1. Connect to the web server then click IP Setting.
2. Edit the settings as required. To enable DHCP addressing, tick the DHCP checkbox.
3. Click Submit to send the new settings to the device.

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Configure IoT settings

The Modbus TCP Card supports soft starter status monitoring over IoT. The card
cannot control or program the soft starter.

NOTE
Version 1.x of the Modbus TCP Card does not support IoT operation.

• Configure MQTT settings

1. Connect to the web server then click Configuration > MQTT Client.
2. Tick the Enable checkbox to enable MQTT client operation. The MQTT client is
enabled by default.
3. Click Connection then configure the settings as required.
4. Use Connection > Actions to select which information the card will publish.
5. Click Submit to save all settings in the card.

• Configure OPC UA settings

1. Connect to the web server then click Configuration > OPC UA Server.
2. Tick the Enable checkbox to enable OPC UA client operation. The OPC UA client is
enabled by default.
3. Click Server Configuration then configure the settings as required.
4. Use Actions to select the actions for different object instances.
5. Click Submit to save all settings in the card.

Modbus TCP Card (710-16501-00C) 9

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Scanning the network

If you cannot connect to the web server and cannot physically access the soft starter,
use the Ethernet Device Configuration software to scan the network and identify the
device. Changes made via the software cannot be stored permanently in the device and
will be lost when control power is cycled.

The Ethernet Device Configuration Tool is available from your local supplier.

NOTE
If your PC has a firewall enabled, you must add the tool to the list of
authorised programs.
To identify the device using the Ethernet Device Configuration Tool:
1. Start the Ethernet Device Configuration Tool.
2. Click on Search Devices. The software will search for connected devices.

3. Use the IP address to connect to the device via the web server.

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4. PLC configuration
The PLC must be configured to map registers within the device to addresses within the
PLC.

The device must be configured directly in the PLC. No additional files are required.

5. Ground fault protection

NOTE
Ground fault protection is only available on ground fault enabled cards, with
soft starters running a compatible version of software. Contact your supplier
for assistance.

5.1 Overview
The Modbus TCP Card can detect ground current and trip before the equipment is
damaged.
Ground fault protection requires a 1000:1 or 2000:1 current transformer (not supplied).
The CT should be rated 1 VA or 5 VA. The soft starter can be configured to trip at 1
A~50 A. If ground fault current rises above 50 A, the soft starter will trip immediately.
Parameter 40C Ground Fault Trip Active selects when ground fault protection is active.

5.2 Connect the CT to the ground fault inputs

To use ground fault protection, a common mode current transformer (CT) must be
installed around all three phases. Use a 1000:1 or 2000:1 CT with rating of 1 VA or 5 VA
and set parameter 40E Ground Fault CT Ratio to match. Connect the CT to the ground
fault terminals (G1, G2, G3).
For maximum protection, the CT should be installed on the input side of the soft
starter.

Modbus TCP Card (710-16501-00C) 11

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5.3 Configure ground fault protection settings

Ground fault protection settings must be set in the soft starter.
Parameter Parameter name Description
40A Ground Fault Sets the trip point for ground fault protection.
Level
40B Ground Fault Slows the Modbus TCP Card's response to ground fault
Delay variation, avoiding trips due to momentary fluctuations.
40C Ground Fault Selects when a ground fault trip can occur.
Trip Active
40D Ground Fault Selects the soft starter's response to the protection
Action event.
40E Ground Fault CT Set to match the ratio of the ground current measuring
Ratio CT.

6. Operation
The Modbus TCP Card must be controlled by a Modbus client (such as a PLC) which
complies with the Modbus Protocol Specification. For successful operation, the client
must also support all functions and interfaces described in this document.

NOTE
The available features and parameter details may vary according to the model
and software version of the starter. Refer to the soft starter user manual for
details of parameters and supported features.

6.1 Device classification

The Modbus TCP Card is a Modbus server and must be managed by a Modbus client
over Ethernet.

6.2 Ensuring safe and successful control

Data written to the device will remain in its registers until the data is overwritten or
the device is reinitialised.
If the soft starter may be controlled via Command Override (parameter 7A) or may be
disabled via the reset input (terminals 10, 11) fieldbus commands should be cleared
from the registers. If a command is not cleared, it will be re-sent to the starter once
fieldbus control resumes.

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6.3 Feedback LEDs

TX/RX2 TX/RX1 STATUS
Port 1 Port 2 Keypad

17821.A
LINK 2 LINK 1 ERROR

LED name LED state Description

Error Off No error.
Flashing System error.
On Communication error.
Status Off Device is not powered up.
Slow flash Ready but not configured.
Fast flash Communication has been established.
Link x Off No network connection.
On Connected to a network.
TX/RX x Flashing Operating normally.
Off No network connection.

7. Modbus registers
NOTE
The available features and parameter details may vary according to the model
and software version of the starter. Refer to the soft starter user manual for
details of parameters and supported features.
NOTE
All references to registers mean the registers within the card unless otherwise
stated.

7.1 Command and configuration registers (read/write)

Register Description Bits Details
40001 Command 0 to 7 To send a command to the starter, write the
(single write) required value:
00000000 = Stop
00000001 = Start
00000010 = Reset
00000100 = Quick stop (coast to stop)
00001000 = Forced communication trip
00010000 = Start using Parameter Set 1
00100000 = Start using Parameter Set 2
01000000 = Reserved
10000000 = Reserved
8 to 14 Reserved
15 Must = 1

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Register Description Bits Details

40002 ~ Reserved
40008
40009 ~ Parameter 0 to 15 Manage soft starter programmable
40xxx management parameters.
(single/multiple read
or multiple write)

7.2 Parameter management

Parameters can be read from and written to the starter. When writing parameters to
the soft starter, every parameter will be updated to match the values in the PLC.

NOTE
While parameters are being written, the starter cannot start/stop the motor.
The Modbus TCP protocol limits read/write operations to a maximum of 123 registers
at one time. The registers must be consecutive.

To avoid loss of communications due to an unintentional change of network

configuration, write the network address parameter settings before writing start/stop
parameter settings.

When writing parameters to the soft starter, we recommend the following procedure:
1. Configure all soft starter parameter values in the PLC as required, including IP
address, Gateway Address, Subnet Mask and DHCP configuration.
2. Write the parameter block that includes the network parameter settings from the
PLC to the soft starter.
3. Write the other parameter blocks from the PLC to the starter until all parameter
values have been written.
NOTE
For reliable operation, the parameter block containing network configuration
settings must be written first.

7.3 Status reporting registers (read only)

Register Description Bits Details
30003 ~ Reserved
30008
30600 Product information 0 to 5 Binary protocol version
6 to 8 Reserved
9 to 15 Product type code:
12 = EMX4e
13 = EMX4i
30601 Model number 0 to 7 Reserved
8 to 15 Soft starter model ID

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Register Description Bits Details

30602 Reserved
30603 Reserved
30604 Starter state 0 to 4 0 = Reserved
1 = Ready
2 = Starting
3 = Running
4 = Stopping
5 = Not ready (restart delay, restart
temperature check, run simulation, reset
input is open)
6 = Tripped
7 = Programming mode
8 = Jog forward
9 = Jog reverse
5 1 = Warning
6 0 = Uninitialised
1 = Initialised
7 Command source
0 = Remote Keypad, Digital Input, Clock
1 = Network
8 Reserved
9 0 = Negative phase sequence
1 = Positive phase sequence
10 to 15 Reserved
30605 Current 0 to 13 Average rms current across all three phases
14 to 15 Reserved
30606 Current 0 to 9 Current (% motor FLC)
10 to 15 Reserved
30607 Motor temperature 0 to 7 Motor thermal model (%)
8 to 15 Reserved
30608 Power 0 to 11 Power
12 to 13 Power scale
0 = Multiply power by 10 to get W
1 = Multiply power by 100 to get W
2 = Power (kW)
3 = Multiply power by 10 to get kW
14 to 15 Reserved
30609 % Power factor 0 to 7 100% = power factor of 1
8 to 15 Reserved
30610 Voltage 0 to 13 Average rms voltage across all three phases
14 to 15 Reserved

Modbus TCP Card (710-16501-00C) 15

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Register Description Bits Details

30611 Current 0 to 13 Phase 1 current (rms)
14 to 15 Reserved
30612 Current 0 to 13 Phase 2 current (rms)
14 to 15 Reserved
30613 Current 0 to 13 Phase 3 current (rms)
14 to 15 Reserved
30614 Voltage 0 to 13 Phase 1 voltage
14 to 15 Reserved
30615 Voltage 0 to 13 Phase 2 voltage
14 to 15 Reserved
30616 Voltage 0 to 13 Phase 3 voltage
14 to 15 Reserved
30617 Parameter list 0 to 7 Parameter list minor revision
version number 8 to 15 Parameter list major version
30618 Digital input state 0 to 15 For all inputs, 0 = open, 1 = closed (shorted)
0 = Start/Stop
1 = Reserved
2 = Reset
3 = Input A
4 = Input B
5 to 15 = Reserved
30619 Trip code 0 to 7 Refer to Trip codes on page 20
8 to 15 Reserved
30620 Reserved
30621 Frequency 0 to 15 Frequency (Hz)
30622 Ground current 0 to 15 Ground current (A)
30623~ Reserved
30631
NOTE
The reset input is normally closed by default. If parameter 7I Reset/Enable
Logic is set to normally open, the reported state will be inverted (0 = closed, 1
= open).
NOTE
For models EMX4x-0064B and smaller, current reported via communications
is 10 times greater than the actual value (displayed on the keypad).
NOTE
Frequency reported via communications is 10 times greater than the actual
value (displayed on the keypad).

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7.4 Legacy mode

The Modbus TCP Card can also operate in Legacy Mode, which uses the same
registers as the clip-on Modbus RTU Module, supplied by AuCom for use with older
soft starters. Some registers differ from those specified in the Modbus Protocol
Specification.

Initialising Legacy Mode

If the card has been operating in Standard Mode, it must be reset before
communicating in Legacy Mode. To initialise the card for Legacy Mode, either:
• cycle control power or
• reset register 40001 to zero (write zero to bits 0~15)

Registers
NOTE
Legacy Mode reports read-only status information in registers 40003 onwards,
to match the register definitions of the clip-on Modbus Module for use with
older soft starters. Identical data is also available via registers 30003 onwards.
Register Description Bits Details
40001 Reserved
40002 Command 0 to 2 To send a command to the starter, write the
(single write) required value:
1 = Start
2 = Stop
3 = Reset
4 = Quick stop (coast to stop)
5 = Forced communication trip
6 = Start using Parameter Set 1
7 = Start using Parameter Set 2
3 to 15 Reserved
40003 Starter state 0 to 3 1 = Ready
2 = Starting
3 = Running
4 = Stopping (including braking)
5 = Restart delay (including temperature
check)
6 = Tripped
7 = Programming mode
8 = Jog forward
9 = Jog reverse
4 1 = Positive phase sequence (only valid if bit
6 = 1)
5 1 = Current exceeds FLC

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Register Description Bits Details

6 0 = Uninitialised
1 = Initialised
7 to 15 Reserved
40004 Reserved
40005 Motor current 0 to 7 Average rms current across all three phases
8 to 15 Reserved
40006 Motor temperature 0 to 7 Motor thermal model (%)
8 to 15 Reserved
40007 Reserved
40008 Reserved
40009 Parameter 0 to 7 Manage soft starter programmable
~ management parameters. Refer to the relevant soft
40xxx (single/multiple read starter literature for a complete parameter
or multiple write) list.
8 to 15 Reserved
40600 Product information 0 to 5 Binary protocol version
6 to 8 Reserved
9 to 15 Product type code:
12 = EMX4e
13 = EMX4i
40601 Model number 0 to 7 Reserved
8 to 15 Soft starter model ID
40602 Reserved
40603 Reserved
40604 Starter state 0 to 4 0 = Reserved
1 = Ready
2 = Starting
3 = Running
4 = Stopping
5 = Not ready (restart delay, restart
temperature check, run simulation, reset
input is open)
6 = Tripped
7 = Programming mode
8 = Jog forward
9 = Jog reverse
5 1 = Warning
6 0 = Uninitialised
1 = Initialised

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Register Description Bits Details

7 Command source
0 = Remote Keypad, Digital Input, Clock
1 = Network
8 Reserved
9 0 = Negative phase sequence
1 = Positive phase sequence
10 to 15 Reserved
40605 Current 0 to 13 Average rms current across all three phases
14 to 15 Reserved
40606 Current 0 to 9 Current (% motor FLC)
10 to 15 Reserved
40607 Motor temperature 0 to 7 Motor thermal model (%)
8 to 15 Reserved
40608 Power 0 to 11 Power
12 to 13 Power scale
0 = Multiply power by 10 to get W
1 = Multiply power by 100 to get W
2 = Power (kW)
3 = Multiply power by 10 to get kW
14 to 15 Reserved
40609 % Power factor 0 to 7 100% = power factor of 1
8 to 15 Reserved
40610 Voltage 0 to 13 Average rms voltage across all three phases
14 to 15 Reserved
40611 Current 0 to 13 Phase 1 current (rms)
14 to 15 Reserved
40612 Current 0 to 13 Phase 2 current (rms)
14 to 15 Reserved
40613 Current 0 to 13 Phase 3 current (rms)
14 to 15 Reserved
40614 Voltage 0 to 13 Phase 1 voltage
14 to 15 Reserved
40615 Voltage 0 to 13 Phase 2 voltage
14 to 15 Reserved
40616 Voltage 0 to 13 Phase 3 voltage
14 to 15 Reserved
40617 Parameter list 0 to 7 Parameter list minor revision
version number 8 to 15 Parameter list major version

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Register Description Bits Details

40618 Digital input state 0 to 15 For all inputs, 0 = open, 1 = closed (shorted)
0 = Start/Stop
1 = Reserved
2 = Reset
3 = Input A
4 = Input B
5 to 15 = Reserved
40619 Trip code 0 to 7 Refer to Trip codes on page 20
8 to 15 Reserved
40620~ Reserved
40631
NOTE
The reset input is normally closed by default. If parameter 7I Reset/Enable
Logic is set to normally open, the reported state will be inverted (0 = closed, 1
= open).
NOTE
For models EMX4x-0064B and smaller, current reported via communications
is 10 times greater than the actual value (displayed on the keypad).

7.5 Trip codes

Trip Description
code
255 No trip
1 Excess start time
2 Motor overload
3 Motor thermistor
4 Current imbalance
5 Frequency
6 Phase sequence
7 Overcurrent
8 Power loss
9 Undercurrent
10 Heatsink overtemperature
11 Motor connection
12 Input A trip
13 FLC too high
14 Unsupported option (function not available in inside delta)
15 Communications card fault
16 Network communication
18 Overvoltage

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Trip Description
code
19 Undervoltage
20 Ground fault
23 Parameter out of range
24 Input B trip
26 L1 phase loss
27 L2 phase loss
28 L3 phase loss
29 L1-T1 shorted
30 L2-T2 shorted
31 L3-T3 shorted
33 Time-overcurrent (Bypass overload)
34 SCR overtemperature
35 Battery/clock
36 Thermistor circuit
47 Overpower
48 Underpower
56 Keypad disconnected
57 Zero Speed Detect
58 SCR Itsm
59 Instantaneous overcurrent
60 Rating Capacity
70 Current Read Err L1
71 Current Read Err L2
72 Current Read Err L3
74 Motor Connection T1
75 Motor Connection T2
76 Motor Connection T3
77 Firing Fail P1
78 Firing Fail P2
79 Firing Fail P3
80 VZC Fail P1
81 VZC Fail P2
82 VZC Fail P3
83 Low Control Volts
84~96 Internal fault x. Contact your local supplier with the fault code (X).

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8. Network design
The device supports star, line and ring topologies.

8.1 Star topology

In a star network, all controllers and devices connect to a central network switch.

14697.A
8.2 Line topology
In a line network, the controller connects directly to one port of the first device. The
second Ethernet port connects to another device, which in turn connects to another
device until all devices are connected.
14695.A

NOTE
The device has an integrated switch to allow data to pass through in line
topology. The device must be receiving control power from the soft starter
for the switch to operate.
NOTE
If the connection between two devices is interrupted, the controller cannot
communicate with devices after the interruption point.
NOTE
Each connection adds a delay to communication with the next device.
The maximum number of devices in a line network is 32. Exceeding this
number may reduce the reliability of the network.

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8.3 Ring Topology

In a ring topology network, the controller connects to the first card, via a network
switch. The second Ethernet port of the card connects to another device, which in turn
connects to another device until all devices are connected. The final device connects
back to the switch.
The device supports beacon based ring node configuration.

14696.A
NOTE
The network switch must support loss of line detection.

8.4 Combined topologies

A single network can include both star and line components.
14700.A

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9. Specifications
• Connections
Soft starter ........................................................................ 6-way pin assembly
Contacts ....................................................................................... Gold flash
Network ...................................................................................................... RJ45
• Settings
IP address ............................................. Automatically assigned, configurable
Device name .......................................... Automatically assigned, configurable
• Network
Protocols ................................................................... Ethernet/IP, MQTT, OPC UA
.............................................................. DHCP, ACD (address conflict detection)
Link speed ........................................................ 10 Mbps, 100 Mbps (auto-detect)
Full duplex
Auto crossover
• Power
Consumption (steady state, maximum) ..................................... 35 mA @ 24 VDC
Reverse polarity protected
Galvanically isolated
• Certification
RCM .......................................................................................... IEC 60947-4-2
CE ...................................................................................................... EN 60947-4-2

24 Modbus TCP Card (710-16501-00C)