Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM

User Manual Rev : 00

i-Swift Add-on Module Date : 20-OCT-2018

Protocol Converter Unit

[PCU]

User Manual

Amara Raja Power Systems Ltd Page 1 of 18

 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

INTRODUCTION
Protocol Converter Unit (referred as PCU from here) is developed to convert our 4-wire customized AR protocol into
industry standard 2-wire Modbus (RTU Mode) protocol. PCU is designed such that it is applicable for all ratings and variants
of FCBC and DFCBC iSwift Chargers. PCU module can be simply plugged-in into DB9 connector of Micro Board (MB) in
FCBC (or) Smart Switch (SS) in DFCBC to get started.

Please read further to understand the usage and testing procedure of PCU.

CONNECTIONS
1. Overview:

FIGURE 1: Overview of PCU Module usage

o Explanation:

 PCU module is connected to MB/SS which is preloaded with AR protocol firmware in iSwift Charger. Power
supply (+5V and GND) is delivered to PCU from MB/SS through the same connector.
 The communication between PCU and MB/SS is 4-wire communication as shown in FIGURE1.
 PCU converts the 4-wire (namely TX+, RX+, TX-, RX-) AR protocol commands into 2-wire Modbus
commands internally and gives output signals via 2-wires D+ and D-.
 This output signals can be directly connected to SCADA network or to a PC via USB to RS485 converter.
 A PC with at least one USB port is required for testing.
 A number of Modbus softwares are available for PC.
 Please note that Modbus RTU mode is mandatory in frontend software. Our software recommendations include:
 QModMaster (strongly recommended, free & open-source)
 Mbus Modbus Tester (free)
 Radzio Modbus Master Simulator (free)
 Medford Master Viewer (free)
 ModScan32 (Not free)
 We recommend QModMaster for its simplicity and easy to use User Interface. Detailed QModMaster tutorial is
included in the Manual.

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

 There are 6 on-board LEDs in total to know the Status of PCU:

LED LABEL ON PCU SIGNIFICANCE

HLTHY Blinks fast (continuously) to imply PCU is working normally
AR Blinks when AR command is received from Charger
MB Blinks when MB command is received from PC
S-FCBC Blinks when Single FCBC is connected
D-FCBC Blinks when Dual FCBC is connected
ERR Blinks when request from PC is not valid

2. PCU Connection Procedure in iSwift FCBC Charger:

FIGURE 2: Connection between FCBC Charger and Computer via PCU

o Explanation:

 Plug-in PCU’s CN.1 into CN.5 of Micro Board via DB9 connector provided
 Turn on Charger and observe LEDs glow in PCU which indicates power is OK
 S-FCBC LED in PCU will glow for FCBC Charger based on charger address (1-127) after few seconds
 Connect D+ and D- of PCU (CN.2) into D+ and D- of USB to RS485 Converter respectively as shown:

PCU CN.2 USB to RS485 Converter

D+ D+
D- D-

 Register and Coil addresses for FCBC Charger are mentioned in the following topics of this manual

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

3. PCU Connection Procedure in DFCBC Charger:

FIGURE 3: Connection between DFCBC Charger and Computer via PCU

o Explanation:

 Plug-in CN.1 of PCU into CN.24 of Smart Switch via DB9 connector provided
 Turn on Charger and observe LEDs glow in PCU which indicates power is OK
 D-FCBC LED in PCU will glow for DFCBC Charger based on charger address (128-247) after few seconds
 Connect D+ and D- of PCU (CN.2) into D+ and D- of USB to RS485 Converter respectively as shown:

PCU CN.2 USB to RS485 Converter

D+ D+
D- D-

 Register and Coil addresses for DFCBC Charger are mentioned in the following topics of this manual

 Note1: Registers and Parameters are interchangeable words in this Manual

 Note2: Coils and Alarms are interchangeable words in this Manual

4. PCU Testing Procedure:

 First ensure the hardware connections as per the above diagrams.

 Install QModMaster (latest version) software in your computer/laptop with which the protocol converter board is
to be tested.
 Open the software and click on and set appropriate COM Port, Baud Rate: 9600, Data Bits: 8, Stop Bits: 1,
Parity: None, RTS: Disable.
 First you need to ensure that proper slave ID is selected in the QModMaster Software. See table below:

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

FCBC/DFCBC Charger (any voltage or current rating) Slave ID Range

Micro Board 1 - 127
Smart Switch 128 - 247

 Then the following tests needs to be simulated using computer. Go through all 10 steps sequentially.
 Use proper Register, Coil addresses and lengths before starting the scanning process. Valid Function Codes and
Modbus Mode are shown in the following table:

Modbus Mode RTU Remote Terminal Unit (RTU) Mode

Function Code Read Coils (0x01) Read Coils/Charger Alarm Statuses
Function Code Read Input Registers (0x04) Read Registers/Charger Parameters
 STEP-1:

1. Open Modbus simulator software folder where it is placed/installed

2. Double click on QModMaster.exe (Executable Application)

 STEP-2: Click on Options & Select Modbus RTU

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

STEP-3: On selecting Modbus RTU, a pop-up window opens like shown below-

Note: COM port will vary with each PC. Please ensure this selection carefully in Device Manager of PC.

 STEP-4: Once again click on Options & select on Setting. Below pop-up window will be available on screen. Please
select value (Response Timeout (seconds) = 1) as per below figure.
Do not modify other values.

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

 STEP-5: After successful completion of above steps, it’s time for connection, click on Command tab, Select Connect
(if it is not connected, it means there is an issue with USB to RS485 Converter or its Windows driver)

 STEP-6: Please select Slave Addr (Addr = Address) according to i-Swift Charger address
Important Notes:

 Charger address for FCBC : i-Swift Micro Board LCD SET PARAMETER -> CHAR ADDRESS
 Charger address for DFCBC : i-Swift Smart Switch LCD SET PARAMETER -> SS ADDRESS
 Smart Switch address must be inputted into Slave Addr field for DFCBC Charger
 Micro Board address must be inputted into Slave Addr field for FCBC Charger

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

 STEP-7: Scan Rate (ms) should be 2000 (ms = millisecond).

 STEP-8: Most important selection for proper monitoring: Refer TABLE 1 & TABLE 2 for more details.

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

TABLE 1

Title FCBC
TEST-1
Parameter
 Function Code = 0x04
Values
 Start Address = 650
(or)
 No of Registers = 14
Registers
TEST-2
Alarms
 Function Code = 0x01
(or)
 Start Address = 0
Coils
 No of Coils = 40

TABLE 2

Title DFCBC Charger -1 DFCBC Charger -2

TEST-1 TEST-1A
Parameter
 Function Code = 0x04  Function Code = 0x04
Values
 Start Address = 650  Start Address = 684
(or)
 No of Registers = 14  No of Registers = 14
Registers
TEST-2 TEST-2A
Alarms  Function Code = 0x01  Function Code = 0x01
(or)  Start Address = 0  Start Address = 40
Coils  No of Coils = 40  No of Coils = 40

 TABLE 1: TEST-1 and TEST-2 mandatory for FCBC

 TABLE 2: TEST-1, TEST-1A, TEST-2, TEST-2B mandatory for DFCBC
 All tests does not have any predefined sequence

 Based on TEST requirements, we need to select proper Function Code, Start Address & No of Registers.
 Real values like Charger O/P Voltage & Current, Battery Voltage & Current, Load Voltage & Current, Heatsink
temperature etc. comes under Parameter Values/Registers
 Charger Statuses like Charger ON/OFF, Charger Mode, DC OV, DC UV indications, Earth Fault, Battery on discharge
etc. comes under Alarms/Coils
 See Section Modbus Register and Coil Address Mapping (Page 11) for respective details

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

STEP-9A: Two ways are there for Data request. One is Single time scan (Read/Write) and another is Continuous Scan.
Click Command Tab & Select Read/Write for single time scanning. Data will be visible on screen.

 STEP-9B: Click Command tab and select Scan. Continuous Scanning starts, data will be visible on screen. Each data
has its own block and address which can be seen upon pointing. All the blocks will be filled with charger parameters like
Load Voltage, Current, Battery Voltage, Current, Heatsink temperature, etc during scanning.

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

 STEP-10 (Optional): Click Command tab and select Clear Table for clearing data which is on screen. To clear/Reset
Packet & Error count Click Command Tab & Select Reset Counter

 Packets : Master (Laptop/PC) send request to Slave (i-Swift) via PCU, Packets counter will increment by each request
 Errors : For each request, if i-Swift does not respond, then Errors counter will update increment

Important to Note:

SCAN process must be STOPPED before changing from one test to another.

If scan process is under progress user cannot change Function Code, Start Address and No of registers/coils. All will be in
disabled mode.

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

MODBUS REGISTER AND COIL ADDRESS MAPPING

Point to remember:

 Addresses are specific for each parameter. Please ensure this while testing.

The following table consists of FCBC Charger display parameters with Register addresses:

FCBC Parameter Data Type Register Address (Dec) Register Address (Hex)
Charger output voltage Word (Units of 100mV) 650 028A
Charger output current Word (Units of 100mA) 651 028B
Load voltage Word (Units of 100mV) 652 028C
Load current Word (Units of 100mA) 653 028D
Battery voltage Word (Units of 100mV) 654 028E
Battery current Word (Units of 100mA) 655 028F
#Reserved for future --- --- ---
Heat Sink temperature Byte (Units of 1ᵒC) 657 0291
Charger AC R-Y voltage Word (Units of 100mV) 658 0292
Charger AC Y-B voltage Word (Units of 100mV) 659 0293
Charger AC B-R voltage Word (Units of 100mV) 660 0294
Charger AC R current Word (Units of 100mA) 661 0295
Charger AC Y current Word (Units of 100mA) 662 0296
Charger AC B current Word (Units of 100mA) 663 0297

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

The following table consists of FCBC Alarm/Coil addresses:

Coil Address Coil Address

FCBC Alarm Condition Data Type
(Dec) (Hex)
1 = Charger ON
Charger ON Coil (Bit) 0 0000
0 = Charger OFF
1 = Charger in Float mode
Float mode Coil (Bit) 1 0001
0 = Charger in another mode
1 = Charger in Boost mode
Boost mode Coil (Bit) 2 0002
0 = Charger in another mode
1 = Charger in Auto mode
Auto mode Coil (Bit) 3 0003
0 = Charger in another mode

# Reserved for future --- --- --- ---

# Reserved for future --- --- --- ---

# Reserved for future --- --- --- ---

# Reserved for future

--- --- --- ---

# Reserved for future --- --- --- ---

# Reserved for future --- --- --- ---

1 = Earth fault occurred

Earth fault Coil (Bit) 10 000A
0 = No earth fault occurred
1 = SCR fuse fail
SCR fuse fail Coil (Bit) 11 000B
0 = No SCR fuse fail
1 = Battery fuse fail
Battery fuse fail Coil (Bit) 12 000C
0 = No Battery fuse fail

# Reserved for future --- --- --- ---

Heat Sink (HS) 1 = HS temperature high

temperature high Coil (Bit) 14 000E
0 = HS temperature is within limit

# Reserved for future --- --- --- ---

# Reserved for future --- --- --- ---

Charger DC Under Voltage 1 = DC UV occurred
(DC UV) Coil (Bit) 17 0011
0 = DC UV not occurred
1 = Charger failed
Charger fail Coil (Bit) 18 0012
0 = Charger not failed

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

# Reserved for future --- --- --- ---

1 = AC is within limit
AC fail Coil (Bit) 20 0014
0 = No AC or out of limit
1 = Blocking diode got shorted
Blocking diode short Coil (Bit) 21 0015
0 = No Blocking diode short
1 = Battery on discharge
Battery on discharge Coil (Bit) 22 0016
0 = Battery not on discharge
Charger DC OV indication 1 = DC OV occurred
Coil (Bit) 23 0017
0 = DC OV not occurred
1 = Load OV occurred
Load Over Voltage (OV) Coil (Bit) 24 0018
0 = Load OV not occurred
1 = Load UV occurred
Load Under Voltage (UV) Coil (Bit) 25 0019
0 = Load UV not occurred
1 = Battery OV occurred
Battery Over Voltage (OV) Coil (Bit) 26 001A
0 = Battery OV not occurred
Battery Under Voltage 1 = Battery UV occurred
Coil (Bit) 27 001B
(UV) 0 = Battery UV not occurred

# Reserved for future --- --- --- ---

1 = AC input breaker trip

AC input breaker trip Coil (Bit) 29 001D
0 = No AC input breaker trip
1 = DC output breaker trip
DC output breaker trip Coil (Bit) 30 001E
0 = No DC output breaker trip

# Reserved for future --- --- --- ---

# Reserved for future --- --- --- ---

1 = DFCBC parallel enabled

DFCBC parallel Coil (Bit) 33 0021
0 = DFCBC parallel disabled
1 = Filter fuse fail
Filter fuse fail Coil (Bit) 34 0022
0 = No Filter fuse fail

# Reserved for future --- --- --- ---

1 = AC shutdown required
AC shutdown Coil(Bit) 36 0024
0 = AC shutdown not required
1 = DFCBC enabled
DFCBC or FCBC Coil(Bit) 37 0025
0 = FCBC enabled
1 = FC-FCBC enabled
FC- FCBC Coil(Bit) 38 0026
0 = FC-FCBC disabled
1 = DFCBC Standby enabled
DFCBC standby Coil(Bit) 39 0027
0 = DFCBC Standby disabled

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

The following table contains DFCBC Charger Parameters/Register addresses:

Charger 1 Charger 2
DFCBC Parameter Data Type Register Address Register Address
(Dec) (Hex) (Dec) (Hex)
Charger output voltage Word (Units of 100mV) 650 028A 684 02AC
Charger output current Word (Units of 100mA) 651 028B 685 02AD
Load voltage Word (Units of 100mV) 652 028C 686 02AE
Load current Word (Units of 100mA) 653 028D 687 02AF
Battery voltage Word (Units of 100mV) 654 028E 688 02B0
Battery current Word (Units of 100mA) 655 028F 689 02B1
#Reserved for future --- --- --- --- ---
Heat Sink temperature Byte (Units of 1ᵒC) 657 0291 691 02B3
Charger AC R-Y voltage Word (Units of 100mV) 658 0292 692 02B4
Charger AC Y-B voltage Word (Units of 100mV) 659 0293 693 02B5
Charger AC B-R voltage Word (Units of 100mV) 660 0294 694 02B6
Charger AC R current Word (Units of 100mA) 661 0295 695 02B7
Charger AC Y current Word (Units of 100mA) 662 0296 696 02B8
Charger AC B current Word (Units of 100mA) 663 0297 697 02B9

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

The following table consists of DFCBC Charger Alarm/Coil addresses:

Charger 1 Charger 2
DFCBC Alarm Condition Data Type Coil Address Coil Address
(Dec) (Hex) (Dec) (Hex)
1 = Charger ON
Charger ON Coil (Bit) 0 0000 40 0028
0 = Charger OFF
1 = Charger in Float mode
Float mode Coil (Bit) 1 0001 41 0029
0 = Charger in another mode
1 = Charger in Boost mode
Boost mode Coil (Bit) 2 0002 42 002A
0 = Charger in another mode
1 = Charger in Auto mode
Auto mode Coil (Bit) 3 0003 43 002B
0 = Charger in another mode
# Reserved for future --- --- --- --- --- ---

# Reserved for future --- --- --- --- --- ---

# Reserved for future --- --- --- --- --- ---

# Reserved for future --- --- --- --- --- ---

# Reserved for future --- --- --- --- --- ---

# Reserved for future --- --- --- --- --- ---

1 = Earth fault occurred
Earth fault Coil (Bit) 10 000A 50 0032
0 = No earth fault occurred
1 = SCR fuse fail
SCR fuse fail Coil (Bit) 11 000B 51 0033
0 = No SCR fuse fail
1 = Battery fuse fail
Battery fuse fail Coil (Bit) 12 000C 52 0034
0 = No Battery fuse fail
# Reserved for future --- --- --- --- --- ---

Heat Sink (HS) 1 = HS temperature high

Coil (Bit) 14 000E 54 0036
temperature high 0 = HS temperature is within limit
# Reserved for future --- --- --- --- --- ---

# Reserved for future --- --- --- --- --- ---

Charger DC Under 1 = DC UV occurred

Coil (Bit) 17 0011 57 0039
Voltage (DC UV) 0 = DC UV not occurred
1 = Charger failed
Charger fail Coil (Bit) 18 0012 58 003A
0 = Charger not failed
# Reserved for future --- --- --- --- --- ---

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

1 = AC is within limit
AC fail Coil (Bit) 20 0014 60 003C
0 = No AC or out of limit
1 = Blocking diode got shorted
Blocking diode short Coil (Bit) 21 0015 61 003D
0 = No Blocking diode short
1 = Battery on discharge
Battery on discharge Coil (Bit) 22 0016 62 003E
0 = Battery not on discharge
Charger DC OV 1 = DC OV occurred
Coil (Bit) 23 0017 63 003F
Indication 0 = DC OV not occurred
Load Over Voltage 1 = Load OV occurred
Coil (Bit) 24 0018 64 0040
(OV) 0 = Load OV not occurred
Load Under Voltage 1 = Load UV occurred
Coil (Bit) 25 0019 65 0041
(UV) 0 = Load UV not occurred
Battery Over Voltage 1 = Battery OV occurred
Coil (Bit) 26 001A 66 0042
(OV) 0 = Battery OV not occurred
Battery Under Voltage 1 = Battery UV occurred
Coil (Bit) 27 001B 67 0043
(UV) 0 = Battery UV not occurred
# Reserved for future --- --- --- --- --- ---
1 = AC input breaker trip
AC input breaker trip Coil (Bit) 29 001D 69 0045
0 = No AC input breaker trip
1 = DC output breaker trip
DC output breaker trip Coil (Bit) 30 001E 70 0046
0 = No DC output breaker trip
# Reserved for future --- --- --- --- --- ---

# Reserved for future --- --- --- --- --- ---

1 = DFCBC parallel enabled
DFCBC parallel Coil (Bit) 33 0021 73 0049
0 = DFCBC parallel disabled
1 = Filter fuse fail
Filter fuse fail Coil (Bit) 34 0022 74 004A
0 = No Filter fuse fail
Charger OK but Battery 1 = Charger OK but Battery on discharge
Coil (Bit) 35 0023 75 004B
discharge 0 = No discharge while charger OK
1 = AC shutdown required
36 0024
AC shutdown 0 = AC shutdown not required Coil (Bit) 76 004C
1 = DFCBC enabled
DFCBC or FCBC Coil (Bit) 37 0025 77 004D
0 = FCBC enabled
1 = FC-FCBC enabled
FC- FCBC Coil (Bit) 38 0026 78 004E
0 = FC-FCBC disabled
1 = DFCBC Standby enabled
DFCBC standby Coil (Bit) 39 0027 79 004F
0 = DFCBC Standby disabled

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 Protocol Converter Unit (PCU) Ref : RAD-iSwift-PCU-UM
User Manual Rev : 00
i-Swift Add-on Module Date : 20-OCT-2018

***Note***
||| Some fields in above tables are reserved for future use and marked as #Reserved for future |||

TROUBLESHOOTING INFORMATION:
Modbus Software showing (1) error while connection, (2) not showing any values/parameters:
a. Ensure COM Port number and hardware connections again
b. Ensure Register and Coil addresses and lengths (incorrect values will not give output)
c. Check if drivers are installed properly in Windows for USB to RS485 Converter and is detectable
d. Check Charger address in SS/MB. Please follow address range as per manual

LEGEND:
ABBREVIATION FULL FORM
SS SMART SWITCH
MB MICRO BOARD
COM COMMUNICATION
FCBC FLOAT-CUM BOOST CHARGER
DFCBC DUAL FLOAT-CUM BOOST CHARGER
RYB RED YELLOW BLUE
OV OVER-VOLTAGE
UV UNDER-VOLTAGE
ADDR ADDRESS
PCU PROTOCOL CONVERTER UNIT

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