DataLink DL-4000 Manual - Congrav LM3 To Modbus

DATALINK
Congrav L/M-3
to
MODBUS™
(and Modbus Ethernet TCP/IP™)
DL-4000 COMMUNICATION CONTROLLER
Rev: 1.03 Sep 10, 2010
DL-4000 VERSION: 1.10 or higher

Congrav L/M-3 VERSION:
HGC 1.82 or higher
NA 1.32 or higher
Information in this document is subject to change without notice. Brabender Technologie Inc. assumes no responsibility for any errors or
omissions which may affect this performance of any system based on the contents of this document.
This document contains proprietary information. Therefore, no part of this manual may be reproduced or transmitted in any form or by
any means, electronic or mechanical, including photocopying and recording, for any purpose other than those approved by Brabender
Technologie Inc.
Brands and product names are trademarks or registered trademarks of their respective holders.
For further information contact:
Brabender Technologie Inc.
6500 Kestrel Road
Mississauga, Ontario, L5T 1Z6
Telephone:(905) 670-2933
Facsimile: (905) 670-2557
Congrav L/M-3 to Modbus™ – Communication Controller Manual
TABLE OF CONTENTS
1. INTRODUCTION............................................................................................................................................... 4
2. DATALINK SPECIFICATIONS FOR CONGRAV L/M-3 INTERFACE ........................................................ 4
3. HARDWARE...................................................................................................................................................... 5
3.1 DL-4000 to Congrav L/M-3 Connection............................................................................................. 5
3.2 DL-4000 to Modbus Host Connection ................................................................................................ 5
4. SOFTWARE ....................................................................................................................................................... 6
4.1 Communication with Modbus ............................................................................................................. 6
4.2 Communication with Congrav L/M-3 ................................................................................................. 6
5. USE OF THE DL-4000 COMMUNICATION CONTROLLER ........................................................................ 7
6. SAMPLE APPLICATION – READ AND WRITE SETPOINT ........................................................................ 8
6.1 Sample #1 – Read and Write Setpoint with Modicon Bridge/Multiplexer (BM85)............................ 8
6.2 Sample #2 – Read and Write Setpoint with Telemecanique Ethernet Bridge (ETG module)............. 13
7. APPENDIXES .................................................................................................................................................... 18
A. Modbus Addressing in DL-4000 .......................................................................................................... 19
1. Write data to Congrav L/M-3 ................................................................................................. 20
2. Read data from Congrav L/M-3.............................................................................................. 38
3. Read communication status .................................................................................................... 69
B. DATALINK Configuration .................................................................................................................. 70
C. HONEYWELL Addendum .................................................................................................................. 71
Rev 1.03 Sep, 2010 Supersedes: Rev 1.02 PAGE 3

1. INTRODUCTION
The Congrav™ line of gravimetric Loss in Weight or weigh belt controllers is provided with a serial interface port
designated for the plant (host) interface.
The communication protocol used is Siemens RK-512 with the 3964R procedure. This protocol is capable of being
converted to Modbus (and Modbus Ethernet TCP/IP) using the DataLink communication controller (and
Telemecanique Connexium Ethernet Gateway). The present documentation refers to the model DL-4000 with the
standard Modbus protocol (and Telemecanique module TSXETG100).
2. DATALINK SPECIFICATIONS FOR CONGRAV L/M-3 INTERFACE
The purpose of the DataLink controller is to provide easy interface between the Congrav L/M-3 controller and a
Modbus (Modbus Ethernet TCP/IP) Host where remote access of the feeder(s) is required. All interface software
being fully developed and the application requiring only data handling internally.
To achieve that goal the communication unit is designed to read selected information from the Congrav L/M-3 and to
write selected information to the Congrav L/M-3. The information read from the Congrav L/M-3 is stored in an
internal database. Information to be written to the Congrav L/M-3 is read also from the internal database. This
database can be accessed by a Modbus Host using the standard Modbus protocol.
The information from/to the Congrav L/M-3 is processed in commands; each command reads/writes specific data.
Each read command has its own flag to determine whether or not to perform the command. These flags are managed
according to the specific application.
Remark: These flags are necessary because the Congrav L/M-3 can process only up to ten commands per second.
Therefore, only the commands required for the application should be active.
The communication unit shows also the communication status with the Congrav L/M-3.
All the information mentioned above is accessed via the Modbus as described in Appendix A – Modbus addressing
in DL-4000.

3. HARDWARE
The hardware used for the communication with the Congrav L/M-3 consists of the DataLink DL-4000 unit with two
cables, one connecting to the Modbus Host and the other to the Congrav L/M-3.
3.1 DL-4000 to Congrav L/M-3 Connection
The DL-4000 is connected to the Congrav L/M-3 through a 4 pin (EURO) connector on the rear panel –
labeled CHB. The connections are made according to the following pinouts for the DL-4000 and
Congrav L/M-3.
DL-4000 Congrav L/M-3

4 pin 9 Pin
(EURO) (Male)
1 RS-422 7 (RX-)
2 9 (TX-)
3 8 (TX+)
4 6 (RX+)
Remark: Pin No. 1 on the EURO connector is the one closer to connector CHC and pin No. 4 is
closer the edge of the unit.
3.2 DL-4000 to Modbus Host Connection
The DL-4000 is connected to the Modbus Host through the port labeled CHA in either one of the
following two ways:
• RS-232C communication: 9 pin DB9M (male) connector on the front panel.
• RS-485 communication: 4 pin (EURO) connector on the rear panel.
The connections are made according to the following pinouts for the DL-4000 and Modbus Host (the
wiring provided for the Host is only the minimum and additional connections may be required, according
to the Host used).
DL-4000 Modbus
9 pin Host (Typical)
Female Female
9 pin 25 pin
1 (SHLD) RS-232C
5 (GND) 5 7
3 (TX) 2 3
2 (RX) 3 2
DL-4000 Modbus
4 pin Host
(EURO) (Typical)
1 (TX-) RS-485 RX-

2 (RX-) TX-
3 (RX+) RX+
4 (TX+) TX+
Remarks: 1. Pin No. 1 on the EURO connector is the one closer to the power connector and pin No.
4 is closer the CHC connector.
2. For two wire RS-485, jumper pins 1-2 and 3-4 for (-) and (+) wires respectively.

4. SOFTWARE
The software for the communication with Congrav L/M-3 and with Modbus is part of the DL-4000 firmware, which
includes the following modes of operation:
ON-LINE – Communication with Modbus on port A (CHA) and with Congrav L/M-3 on port B (CHB).
Detailed description of operation is provided in this manual.
OFF-LINE – Configuration, Diagnostic and Debug mode. Very rarely required. Therefore, details of
operation are provided in DataLink’s user’s manual. For configuration please see Appendix B.
4.1 Communication with Modbus
The communication with Modbus is written in assembler language and is part of the standard DL-4000
product. This software is compiled, and the code generated is used to program a flash EPROM, which
becomes part of the DL-4000 firmware.
4.2 Communication with Congrav L/M-3
The communication with Congrav L/M-3 is written in assembler language and is a custom software for
this customized DL-4000. This software is compiled, linked (together with the Modbus software) and the
code generated is used to program a flash EPROM, which becomes part of the DL-4000 firmware.
For a Modbus Host the DL-4000 is a Modbus station that contains a database similar to a PLC.
Therefore, to communicate with the DL-4000, the Modbus Host has to access the correct addresses as
detailed in Appendix A – Modbus addressing in DL-4000.
The database in the DL-4000 contains values. The representation of these values (i.e. bits, integers or
floating points) is determined by the Modbus Host as specified in Appendix A.

5. USE OF THE DL-4000 COMMUNICATION CONTROLLER
The DL-4000 is designed with two separate virtual databases – one for values “Read” from the Congrav L/M-3 and
one for values to “Write” to the Congrav L/M-3.
The values “Read” from the Congrav L/M-3 are controlled by the DL-4000 with flags in the database. These flags
are constantly monitored by the software. Setting a flag (to a value of 80 hexadecimal or 128 decimal) signals the
software to “Read” the values pertaining to the command associated with that flag.
Each flag has an address in the database and is structured as part of the related command as detailed in Appendix A.
Each “Write” command interrupts the ‘Read’ cycle and is performed immediately. Therefore, “Write” commands
should be done upon value change and/or other specific logic conditions in the application (such as recipe
download), but NOT continuously, as this will practicaly disable the ‘Read’ cycle.
We recommend that each “Write” command is followed by the accordingly “Read” command so that data written to
the Congrav L/M-3 is checked – considering Congrav L/M-3’s response time and entering the appropriate delays in
the application.
Remark: Floating Point values are being converted from one format to another. Therefore, when checking a
Floating Point value a narrow band should be used. For example it is possible that when a value of 100 is
written the value read may be 99.999 or 100.001.
The DL-4000 performs up to ten commands per second to the Congrav L/M-3. Therefore, where response time is of
an importance, we suggest to limit the operations (the “Read” flags set to 80H) to the minimum required.

6. SAMPLE APPLICATION – READ AND WRITE SETPOINT
This section gives two examples of the application required in a MODICON PLC for reading and writing the
setpoint from/to the Congrav L/M-3. The first example is for an application with a Modicon Bridge/Multiplexer
(BM85) for a Modbus PLUS network. The second example is for an application with a Telemecanique ConneXium
Ethernet Gateway (ETG module) for a Modbus Ethernet TCP/IP network.
6.1 Sample #1 – Read and Write Setpoint with Modicon Bridge/Multiplexer (BM85)
This application makes use of a Modicon Bridge/Multiplexer (BM85). This unit enables the PLC (via the
BM85) to issue Modbus Host commands using its Modbus PLUS port (the PLC Modbus port is a slave
and the DL-4000 port is a slave).
The PLC allows up to four MSTR blocks to be simultaneously active in a ladder logic program. It is up to
the application to make sure that this is the case, otherwise unpredicted situations (like lost messages) may
occur.
As this example uses only three MSTR instructions, no attempt was made to ensure that the above
mentioned restriction is addressed.

NETWORK #00001
The first part (lines 1-3) writes the command flag to the DL-4000. This flag tells the DL-4000 to read the actual values of
the Feeder from the Congrav.
This flag is repeatedly written (at a low frequency) to ensure it is written also after a reset or a power failure of the DL-
4000.
The second part (lines 5-7) controls the frequency of polling the values from the DL-4000 on the MODBUS and reads the
actual values of the Feeder. This does not control the frequency of polling from the Congrav itself – this is controlled by the
DL-4000.
1+------------]/[---------------++------------------ +-------------------- +-------------------- +--
| 00001 | | #0010 | | 41001 |
| | | | | |
| | | | | |
| | | | | |
| | | | | |
2+ ++ T1.0 +-- + +--
| | 41010 | | 41011 |
| | | | |
| | | | |
| | | | |
| +------------------ + | |
3+ | MSTR +-------------------- ( )----------
| | #0001 | 00001
| | |
| | |
| | |
| +-------------------- +
4+
|
|
|
|
|
5+------------]/[---------------++------------------ +-------------------- +-------------------- +--
| 00002 | | #0050 | | 41021 |
| | | | | |
| | | | | |
| | | | | |
| | | | | |
6+ ++ T.01 +-- + +--
| | 41030 | | 41031 |
| | | | |
| | | | |
| | | | |
| +------------------ + | |
7+ | MSTR +-------------------- ( )----------
| | #0010 | 00002
| | |
| | |
| | |
| +-------------------- +

MSTR Instruction Data Entry for the Control Block starting at address 41001
Register Data Function

41001 1 Write data
41002 0 Error status – Always “0”
41003 1 Number of registers – Always “1” for the flags
41004 7200 Offset in the 40000 area in the DL-4000 as detailed in Appendix A
41005 21 First routing register – the BM85 address
41006 3 Second routing register – the BM85 port connected to the DL-4000
41007 0 Third routing register – Always “0”
41008 0 Fourth routing register – Always “0”
41009 0 Fifth routing register – Always “0”
The value written to the DL-4000 “The Flag” is taken from register 41011 and it should be either “80H” or “0” as detailed
in Appendix A.

41021 2 Read data
41023 10 Number of registers – only five floating-point values were requested
in this example. This value varies according to the data and the
requirements of the application and should match the one in the
MSTR instruction.
The values read from the DL-4000 are placed in the ten (10) registers starting at 41031 in Modicon floating-point format.

NETWORK #00002
Write a new set-point value. The first part (lines 1-3) detects when a new value is entered. The second part (lines 4-7)
sends the new value and updates the stored value. The DL-4000 receives this new value and sends it to the Congrav.
1+----------------------------- +-------------------- +- +------------------------------------------ ( )-----
| | 41111 | | 00005
| | | |
| | | |
| | | |
| | | |
2+ + +-------------------- + +-------------------- ( )-----
| | 41121 | | 00006
| | | |
| | | |
| | | |
| | | |
3+ + EMTH +------------------------------------------ +
| | CMPFP |
| | |
| | |
| | |
| +-------------------- +
4+------------]/[-------------------] [--------------- +-------------------- +------------------------------------------ +
| 00005 00006 | | |
| | | |
| | | |
| | | |
| | | |
5+------------] [-------------------]/[--------------- + ++------------------ +-- ++------------------ +--
| 00005 00006 | 41111 | | 41101 |
| | | | |
| | | | |
| | | | |
| | | | |
6+ | | + +--
| | 41121 | | 41111 |
| | | | |
| | | | |
| | | | |
| | | | |
7+ | BLKM | | MSTR +--
| | #0002 | | #0002 |
| | | | |
| | | | |
| | | | |
| +------------------ + +------------------ +


41101 1 Write data
41103 2 Number of registers – only one floating-point value is written in this
example. This value varies according to the data and the
MSTR instruction.
The value written to the DL-4000 is taken from two registers starting at 41111 and it is expected to be in Modicon floating-
point format.

6.2 Sample #2 – Read and Write Setpoint with Telemecanique Ethernet Bridge (ETG module)
This application makes use of a Telemecanique ConneXium Ethernet Gateway (TSXETG100). This unit
enables the PLC (via the ETG module) to issue Modbus Host commands using its Ethernet TCP/IP port
(the PLC Modbus port is a slave and the DL-4000 port is a slave).
The PLC allows up to four MSTR blocks to be simultaneously active in a ladder logic program. It is up to
the application to make sure that this is the case, otherwise unpredicted situations (like lost messages) may
occur.
As this example uses only three MSTR instructions, no attempt was made to ensure that the above
mentioned restriction is addressed.

NETWORK #00001
The first part (lines 1-3) writes the command flag to the DL-4000. This flag tells the DL-4000 to read the actual values of
the Feeder from the Congrav.
This flag is repeatedly written (at a low frequency) to ensure it is written also after a reset or a power failure of the DL-
4000.
The second part (lines 5-7) controls the frequency of polling the values from the DL-4000 on the MODBUS (via Ethernet)
and reads the actual values of the Feeder. This does not control the frequency of polling from the Congrav itself – this is
controlled by the DL-4000.
1+------------]/[---------------++------------------ +-------------------- +-------------------- +--
| 00001 | | #0010 | | 41001 |
| | | | | |
| | | | | |
| | | | | |
| | | | | |
2+ ++ T1.0 +-- + +--
| | 41010 | | 41011 |
| | | | |
| | | | |
| | | | |
| +------------------ + | |
3+ | MSTR +-------------------- ( )----------
| | #0001 | 00001
| | |
| | |
| | |
| +-------------------- +
4+
|
|
|
|
|
5+------------]/[---------------++------------------ +-------------------- +-------------------- +--
| 00002 | | #0050 | | 41021 |
| | | | | |
| | | | | |
| | | | | |
| | | | | |
6+ ++ T.01 +-- + +--
| | 41030 | | 41031 |
| | | | |
| | | | |
| | | | |
| +------------------ + | |
7+ | MSTR +-------------------- ( )----------
| | #0010 | 00002
| | |
| | |
| | |
| +-------------------- +


41001 1 Write data
41003 1 Number of registers – Always “1” for the flags
41005 0101 (Hex) The DL-4000 address (low byte). Always “01” in the high byte.
41006 130 First byte of the ETG IP address
41007 50 Second byte of the ETG IP address
41008 3 Third byte of the ETG IP address
41009 151 Fourth byte of the ETG IP address
The value written to the DL-4000 “The Flag” is taken from register 41011 and it should be either “80H” or “0” as detailed
in Appendix A.

41021 2 Read data
41023 10 Number of registers – only five floating-point values were requested
in this example. This value varies according to the data and the
MSTR instruction.
The values read from the DL-4000 are placed in the ten (10) registers starting at 41031 in Modicon floating-point format.

NETWORK #00002
Write a new set-point value. The first part (lines 1-3) detects when a new value is entered. The second part (lines 4-7)
sends the new value and updates the stored value. The DL-4000 receives this new value and sends it to the Congrav.
1+----------------------------- +-------------------- +- +------------------------------------------ ( )-----
| | 41111 | | 00005
| | | |
| | | |
| | | |
| | | |
2+ + +-------------------- + +-------------------- ( )-----
| | 41121 | | 00006
| | | |
| | | |
| | | |
| | | |
3+ + EMTH +------------------------------------------ +
| | CMPFP |
| | |
| | |
| | |
| +-------------------- +
4+------------]/[-------------------] [--------------- +-------------------- +------------------------------------------ +
| 00005 00006 | | |
| | | |
| | | |
| | | |
| | | |
5+------------] [-------------------]/[--------------- + ++------------------ +-- ++------------------ +--
| 00005 00006 | 41111 | | 41101 |
| | | | |
| | | | |
| | | | |
| | | | |
6+ | | + +--
| | 41121 | | 41111 |
| | | | |
| | | | |
| | | | |
| | | | |
7+ | BLKM | | MSTR +--
| | #0002 | | #0002 |
| | | | |
| | | | |
| | | | |
| +------------------ + +------------------ +


41101 1 Write data
41103 2 Number of registers – only one floating-point value is written in this
example. This value varies according to the data and the
MSTR instruction.
The value written to the DL-4000 is taken from two registers starting at 41111 and it is expected to be in Modicon floating-
point format.

7. APPENDIXES

A. Modbus Addressing in DL-4000

The following tables detail the addresses required for a Read/Write operation with the DL-4000.
Each address has the standard Modbus format of 4xxyy where:
4 – Type of data (always 4 for Read and Write registers).
xx – Command number divided by 2.
yy – Offset in words (registers) within the command (plus 50 for odd commands).
Notes:
1. Each floating point value requires two words (registers).
2. The values for “Write” are stored in a different data table than the values for “Read”, therefore at the same address
we may have different values stored for each category – Write or Read.
3. Wherever “Kg” is mentioned it can be either “Kg” or “Lb”.

1. Write data to Congrav L/M-3

Each write command to the Congrav L/M-3 performs a write of all the associated data even if only one value was
changed by the Modbus Host (the other data is added from the DL-4000 database).
Write data to Congrav L/M-3

Command Address Format Description
No.
1 Installation Parameters
40051 Integer High byte - Analog control function (HGC-type only)
or hex 0 – Off
1 – On
Low byte - Congrav L/M-3 mode of operation
0 – No function
1 – Single (HGC-type);
Recipe in Kg (NA-type)
2 – Group (HGC-type);
Recipe in % (NA-type)
3 – Group with 100% control (HGC-type only)
4 – Master/Slave (HGC-type only)
5 – Master/Slave actual value control (HGC-type only)
40052 Integer High byte - Always “0”
or hex Low byte - Memory operations
0 – No function
1 – Not used
2 – Not used
3 – Reset RAM
4 – Init data
40053 Integer Not used
40054 Integer Analogue channel (0-16) (HGC-type only)
40055 Integer Setpoint threshold (1-100%) (HGC-type only)
40056 Integer Setpoint ramp (0-300 sec) (HGC-type only)
2 Printer Parameters
40101 Integer High byte - Print in case of alarm
or hex 0 – No
1 – Yes
Low byte - Print calibration data
0 – No
1 – Feeder 1

8 – Feeder 8
9 – Feeder 9 (HGC-type only)

40102 Integer Congrav L/M-3 Page No.
or hex Low byte - Type of page to print
46h – “F” type
4Bh – “K” type
40104 Integer Print time (0 to 999 min)


No.
4 Feeder preselection
40201 Integer High byte - Feeder 1 preselection
or hex 0 – Preselection off
1 – Preselection on
Low byte - Feeder 2 preselection
or hex Low byte - Feeder 4 preselection
40203 Integer High byte - Feeder 1 Alarm stop
or hex 0 – Do not stop on alarms
1 – Stop on alarms
Low byte - Feeder 2 Alarm stop
40204 Same High byte - Feeder 3 Alarm stop
40205 Same High byte - Feeder 5 preselection
40209 Same High byte - Feeder 9 preselection (HGC-type only)
Low byte - Feeder 10 preselection (HGC-type only)
40211 Same High byte - Feeder 9 Alarm stop (HGC-type only)
Low byte - Feeder 10 Alarm stop (HGC-type only)


No.
5 Feeder modes
40251 Integer High byte - 0 – No function
or hex 1 – GF (H-type and G-type)
2 – VR (H-type only)
3 – VS (H-type only)
4 – DI
5 – CM (H-type only)
6 – GD (H-type);
Bypass (C-type)
7 – VF (H-type only)
8 – B1 (N-type only)
9 – AT (Auto-Tare) (HGC-type only)
10 – M (C-type only)
11 – Not used
12 – Not used
13 – Not used
14 – Not used
16 – A1 (A-type only)
Low byte - 18 – B3 (N-type only)
Feeder 2 mode
40252 Same High byte - Feeder 3 mode
Low byte - Feeder 4 mode
40255 Same High byte - Feeder 9 mode (HGC-type only)
Low byte - Feeder 10 mode (HGC-type only)


No.
6 Delay times for Start/Stop (HGC-type only)
40301 Integer Feeder 1 start delay time
40302 Same Feeder 1 stop delay time
40303 Same Feeder 2 start delay time


No.
7 Alarm and Digital I/O configuration
40351 Integer High byte - Feeder 1 DI #1 function
or hex 0 – Interlocking (HGC-type only)
1 – Refill (H-type);
Auto-tare (G-type)
2 – Gravimetric discharge (GD) (HGC-type only)
3 – Digital Speed
4 – Speed Monitoring
Low byte - Feeder 1 DO #4 function (HGC-type only)
0 – Control deviation +/-
1 – Throughput
2 – Overload
3 – Underload
4 – Alarm Message
40352 Integer High byte - Feeder 1 alarm configuration
or hex (0 – Cut-out; 1 – Report only)
Bit 0 – Speed minimum
Bit 1 – Speed maximum
Bit 2 – Negative control deviation (HGC-type);
Tolerance fault (NA-type)
Bit 3 – Positive control deviation (HGC-type);
Feeding time fault (NA-type)
Bit 4 – Overload
Bit 5 – Underload
Bit 6 – Refill fault (HGN-type);
Discharge (A-type)
Bit 7 – Anti vibration
Low byte - Feeder 1 DI #4 function (HGC-type only)
0 – Interlocking
1 – Refill (H-type);
Auto-tare (G-type)
2 – Gravimetric discharge (GD)
3 – Alarm Reset
4 – Interlocking
40353 Same High byte - Feeder 2 DI #1 function
40354 Same High byte - Feeder 2 alarm configuration


No.
7 40363 Integer High byte - Feeder 7 DI #1 function
(cont’d) or hex Low byte - Feeder 7 DO #4 function (HGC-type only)
40367 Same High byte - Feeder 9 DI #1 function (HGC-type only)
40368 Same High byte - Feeder 9 alarm configuration (HGC-type only)


No.
8 Screen Page Interlocks
40401 Integer High byte - Page F100 Interlocking
or hex 0 – Interlocking off
1 – Interlocking on
Low byte - Not used
40402 Same Same Same as above for Page F110
40405 Same Same Not used
40411 Same Same Same as above for Pages F300 and F301
40414 Same Same Same as above for Page Kxx0*1
40416 Same Same Same as above for Page Kxx1*1 (modes)
40422 Same Same Same as above for Page F150 (HGC-type only)
*1 xx is for all configured feeders; i.e. 01, 02, … 08, 09(HGC-type only), … 16(HGC-type only).


No.
16 Control/Feeding parameters for feeder 1
40801 Floating "P" term of Feeder 1 (HGC-type);
Point Coarse feeding/Discharge (NA-type)
40803 Same "I" term of Feeder 1 (HGC-type);
Fine feeding (NA-type)
40805 Same "D" term of Feeder 1 (HGC-type);
Coarse/Fine switchover (NA-type)
40807 Same Control factor (HC-type);
Always “1” (G-type);
Derivative action point (NA-type)
40809 Same Continuous CM calculation (HC-type);
Feeding time (NA-type)


No.


No.
24 Control parameters for feeder 9 (HGC-type only)
41201 Floating "P" term of Feeder 9
Point
41203 Same "I" term of Feeder 9
41205 Same "D" term of Feeder 9
Always “1” (G-type)
Point
Point
Point
Point


No.
Point
Point
Point
48 Refill levels for feeder 1
42401 Floating Fill level minimum
Point
42403 Same Fill level maximum
Point
Point
Point
Point
Point


No.
Point
Point
56 Refill levels for feeder 9 (HGC-type only)
Point
Point
Point
Point
Point
Point
Point
Point


No.
80 Production parameters for feeder 1
44001 Floating Bulk density (H-type, N-type and A-type);
Point Always “1” (G-type)
44003 Same Checking maximum output (H-type and N-type);
Always “1” (G-type, N-type B1 mode and A-type)
44005 Same Auto-tare
44007 Same Decade switch
44009 Same Volumetric maximum output (HC-type only)


No.
88 Production parameters for feeder 9 (HGC-type only)
44401 Floating Bulk density (H-type);
44403 Same Checking maximum output (H-type);
44453 Checking maximum output (H-type);
44455 Auto-tare
44457 Decade switch
44459 Volumetric maximum output (HC-type only)


No.
112 Total throughput divisor (HGC-type only)
45601 Floating Total throughput divisor
Point
45603 Same Total throughput


No.
128 Group control
or hex Low byte - 0 – No function
1 – Start all preselected feeders
2 – Stop all preselected feeders
3 – Reset alarm all preselected feeders
4 – Reset total throughput
5 – Reset throughput all preselected feeders
6 – Immediate stop
7 – Not used
8 – Key switch on
9 – Key switch off
10 – Interlocking on all preselected feeders
11 – Interlocking off all preselected feeders
12 – Not used
13 – Not used
14 – Batch cutout (NA-type only)
129 Single feeder control
46451 Integer High byte - Feeder 1 control
or hex 0 – No function
1 – Start
2 – Stop
3 – Reset alarm
4 – Not used
5 – Reset Throughput
6 – Immediate stop
7 – Refill
8 – Start sampling (H-type only)
9 – Auto tare
11 – Interlocking off
12 – Not used
13 – Not used
14 – Batch cut-out (NA-type only)
Low byte - Feeder 2 control
46452 Same High byte - Feeder 3 control
46455 Same High byte - Feeder 9 control (HGC-type only)
Low byte - Feeder 10 control (HGC-type only)


No.
144 Group or Master set-point [Kg/h] (HGC-type);
Set-point [Kg] when in Recipe % mode (NA-type)
47201 Floating Group or Master set-point (HGC-type);
Point Set-point [Kg] when in Recipe % mode (NA-type)
145 Feeder set-points [%]
In % of the Master set-point, analog control or GM (HGC-type);
In % of Set-point [Kg] when in Recipe % mode (NA-type)
47251 Floating Feeder 1 set-point
Point
47253 Same Feeder 2 set-point
47267 Same Feeder 9 set-point (HGC-type only)
146 Feeder set-points [Kg/h; Kg]
In Kg/h (HGC-type);
In Kg when in Recipe Kg mode (NA-type)
Point


No.
147 Feeder set-points [%]
In % for Discharge (HGC-type);
Number of batches (0-9999) (NA-type)
Point
148 Feeder set-points [Kg/h] for batch mode B3 (NA-type only)
Point

2. Read data from Congrav L/M-3
To perform a read command from the Congrav L/M-3 the attached flag has to be set, by activating a write MSTR
instruction to the appropriate address.
Each read command from the Congrav L/M-3 performs a read of all the associated data even if only one value is
required by the PLC.
Read data from Congrav L/M-3

No.
1 Installation Parameters
40050 Integer Read flag
or hex 0 – No read
80h – Read
40051 Integer High byte - Analog control function (HGC-type only)
or hex 0 – Off
1 – On
Low byte - Congrav L/M-3 mode of operation
0 – No function
1 – Single (HGC-type);
Recipe in Kg (NA-type)
2 – Group (HGC-type);
Recipe in % (NA-type)
3 – Group with 100% control (HGC-type only)
4 – Master/Slave (HGC-type only)
5 – Master/Slave actual value control (HGC-type only)
or hex Low byte - Memory operations
0 – No function
1 – Not used
2 – Not used
3 – Reset RAM
4 – Init data
40053 Integer Not used
40054 Integer Analogue channel (0-16) (HGC-type only)
40055 Integer Setpoint threshold (1-500%) (HGC-type only)
40056 Integer Setpoint ramp (0-300 sec) (HGC-type only)


No.
2 Printer Parameters
80h – Read
40101 Integer High byte - Print in case of alarm
or hex 0 – No
1 – Yes
Low byte - Print calibration data
0 – No
1 – Feeder 1

8 – Feeder 8

40102 Integer Congrav L/M-3 Page No.
40103 Integer High byte - Always "0"
Low byte - Type of page to print
46h – “F” type
4Bh – “K” type
40104 Integer Print time (0 to 999 min)
3 Type of feeder
80h – Read
40151 Integer High byte - Feeder 1 type
or hex 0 – No feeder connected
1 – H (H-type);
N (N-type)
2–A
3–C
4–G
Low byte - Feeder 2 type
40152 Same High byte - Feeder 3 type
40155 Same High byte - Feeder 9 type (HGC-type only)
Low byte - Feeder 10 type (HGC-type only)


No.
4 Feeder preselection
80h – Read
or hex 0 – Preselection off
1 – Preselection on
or hex Low byte - Feeder 4 preselection
40203 Integer High byte - Feeder 1 Alarm stop
or hex 0 – Do not stop on alarms
1 – Stop on alarms


No.
5 Start conditions and Feeder modes
80h – Read
40251 Integer High byte - Feeder 1 start condition
or hex 0 – All start conditions have been met
1 – Weight < filling level minimum
2 – Not used
3 – Not used
4 – Setpoint > max. output + 10% (HGC-type);
Setpoint > max. batch size (NA-type)
5 – Feeder type is missing
6 – Bulk density = 0
7 – Not used
8 – Fill level minimum < underload
9 – Fill level maximum < fill level minimum
10 – Overload < fill level maximum
11 – Not used
12 – Checked maximum output = 0
13 – Auto tare is missing (GC-type only)
14 – Not used
15 – Not used
16 – Setpoint = 0 (NA-type only)
17 – Feeding time is missing (NA-type only)
18 – Derivative action point missing (NA-type only)
19 – Not used
20 – Weight > Discharge tolerance
21 – Not used
22 – Load cell is missing
23 – Frequency converter is missing
24 – Coriolis Calibration missing
25 – Coriolis Speed missing
26 – Communication fault
Low byte - Feeder 2 start condition
40252 Integer High byte - Feeder 3 start condition
or hex Low byte - Feeder 4 start condition
40253 Integer High byte - Feeder 1 mode
or hex 0 – No mode selected
1 – GF (HGC-type only)
2 – VR (H-type only)
3 – VS (H-type only)
4 – DI
5 – CM (H-type only)
6 – GD (H-type only)
7 – VF (HC-type only)
9 – AT (HGC-type only)
10 – M (C-type only)
11 – Not used
12 – Not used
13 – Not used
14 – Not used


No.
5 40254 Integer High byte - Feeder 3 mode
(cont’d) or hex Low byte - Feeder 4 mode
40255 Same High byte - Feeder 5 start condition
40256 Same High byte - Feeder 7 start condition
40259 Same High byte - Feeder 9 start condition (HGC-type only)
Low byte - Feeder 10 start condition (HGC-type only)


No.
6 Delay times for Start/Stop (HGC-type only)
80h – Read
40301 Integer Feeder 1 start delay time


No.
7 Alarm and Digital I/O configuration
80h – Read
or hex 0 – Interlocking (HGC-type only)
1 – Refill (H-type); Auto-tare (G-type)
2 – Gravimetric discharge (GD) (HGC-type only)
3 – Digital Speed
4 – Speed Monitoring
0 – Control deviation +/-
1 – Throughput
2 – Overload
3 – Underload
4 – Alarm Message
40352 Integer High byte - Feeder 1 alarm configuration
or hex (0 – Cut-out; 1 – Report only)
Bit 0 – Speed minimum
Bit 1 – Speed maximum
Bit 2 – Negative control deviation (HGC-type);
Tolerance fault (NA-type)
Bit 3 – Positive control deviation (HGC-type);
Feeding time fault (NA-type)
Bit 4 – Overload
Bit 5 – Underload
Bit 6 – Refill fault (HGN-type);
Discharge (A-type)
Bit 7 – Anti vibration (H-type and G-type)
0 – Interlocking
1 – Refill (H-type); Auto-tare (G-type)
2 – Gravimetric discharge (GD)
3 – Alarm Reset
4 – Interlocking


No.
7 40361 Same High byte - Feeder 6 DI #1 function
(cont’d) Low byte - Feeder 6 DO #4 function (HGC-type only)
or hex Low byte - Feeder 7 DO #4 function (HGC-type only)

Read data to Congrav L/M-3

No.
8 Screen Page Interlocks
80h – Read
40401 Integer High byte - Page F100 Interlocking
or hex 0 – Interlocking off
Low byte - Not used
40416 Same Same Same as above for Page Kxx1*1 (modes)
*1 xx is for all configured feeders; i.e. 01, 02, … 08, 09(HGC-type only), … 16(HGC-type only).


No.
80h – Read
40807 Same Control factor (HGC-type);
40809 Same Continuous CM calculation (HGC-type);
80h – Read
80h – Read


No.
80h – Read
80h – Read
80h – Read


No.
80h – Read
80h – Read
24 Control/Feeding parameters for feeder 9 (HGC-type only)
80h – Read
Point
41207 Same Control factor
41209 Same Continuous CM calculation
80h – Read
Point


No.
80h – Read
Point
80h – Read
Point
80h – Read
Point
80h – Read
Point
80h – Read
Point


No.
80h – Read
Point
80h – Read
Point
80h – Read
Point
80h – Read
Point
80h – Read
Point
80h – Read
Point


No.
80h – Read
Point
80h – Read
Point
80h – Read
Point
80h – Read
Point
80h – Read
Point
80h – Read
Point
80h – Read
Point


No.
80h – Read
Point
80h – Read
Point
80h – Read
Point
80h – Read
Point
80h – Read
80h – Read


No.
80h – Read
80h – Read
80h – Read
80h – Read


No.
80h – Read
80h – Read
80h – Read
80h – Read


No.
80h – Read
80h – Read
80h – Read
80h – Read


No.
80h – Read
80h – Read
112 Total throughput divisor (HGC-type only)
80h – Read
45601 Floating Total throughput divisor
Point
143 Group set-points and actual values
80h – Read
47151 Floating Installation set-point
Point
47153 Same Group or Master set-point (HGC-type);
Set-point in Kg when in Recipe % mode (NA-type)
47155 Same Actual value of installation


No.
144 Feeder 1 set-points and actual values
80h – Read
47201 Floating Set-point [Kg/h] (HGC-type);
Point Set-point [Kg] (NA-type)
47203 Same Actual value [Kg/h] (HGC-type);
Actual value [Kg] (NA-type)
47205 Same Hopper level [Kg] (HCNA-type);
Belt load [Kg] (G-type)
47207 Same Speed [%]
47209 Same Throughput [Kg]
47211 Same Set-point [%] for Group and Master/Slave operation (HGC-type);
Set-point [%] for Recipe in % mode (NA-type)
47213 Same Set-point [%] for DI (HGC-type);
Batch number (NA-type)
47215 Same Sample [Kg/h] (HGC-type);
Actual batch number (NA-type)
47217 Same Auto tare value [Kg]
47219 Same Control difference [%] (HGC-type);
Batch difference [Kg] (NA-type)
80h – Read


No.
80h – Read
80h – Read


No.
80h – Read
80h – Read


No.
80h – Read
80h – Read


No.
152 Feeder 9 set-points and actual values (HGC-type only)
80h – Read
47601 Floating Set-point [Kg/h]
Point
47603 Same Actual value [Kg/h]
47605 Same Hopper level [Kg] (HC-type);
47611 Same Set-point [%] for Group and Master/Slave operation
47613 Same Set-point [%] for DI
47615 Same Sample [Kg/h]
47619 Same Control difference [%]
80h – Read
Point
80h – Read
Point


No.
80h – Read
Point
80h – Read
Point
80h – Read
Point


No.
80h – Read
Point
80h – Read
Point


No.
176 System status
80h – Read
48801 Integer High byte - System status
or hex Bit 0 – Installation interlocked stopped
Bit 1 – Installation interlocked started
Bit 2 – Start delay time of a feeder run down (HGC-type only)
Bit 3 – Stop delay time of a feeder run down (HGC-type only)
Bit 4 – Installation started
Bit 5 – A feeder in alarm
Bit 6 – Installation stopped
Bit 7 – Start conditions for a feeder not met
Low byte - Start condition for installation
(for pre-selected feeders only)
0 – Installation ready to start
1 – Master component is missing (HGC-type only)
2 – Several master components (HGC-type only)
3 – Group setpoints <> 100% (HGC-type only)
4 – Start conditions for a feeder not met
5 – MM-fault Installation or a feeder
6 – Host computer interface busy
48802 Integer High byte - System status
or hex Bit 0 – Key switch status
Bit 1 – Communication error to a feeder
Bit 2 – Not used
Bit 3 – Not used
Bit 4 – Not used
Bit 5 – Not used
Bit 6 – Not used
Bit 7 – Not used
Low byte - Not used


No.
177 Feeder status and Alarms
80h – Read
48851 Integer High byte - Feeder 1 alarms
or hex 0 – No alarm
1 – Load cell signal failure
2 – Refill fault
3 – Underload
4 – Overload
5 – Negative control deviation (HGC-type only)
6 – Positive control deviation (HGC-type only)
7 – Speed minimum
8 – Speed maximum
9 – Memory module fault
10 – Auto tare fault (GC-type only)
11 – Soft start fault (HGC-type only)
12 – AV fault (HGC-type only)
13 – CM fault (H-type only)
14 – Frequency converter fault
15 – Coriolis speed fault (C-type only)
16 – Tolerance fault (NA-type)
17 – Feeding time fault (NA-type)
18 – Communication fault (HGC-type only)
Low byte - Feeder 2 alarms
or hex Low byte - Feeder 4 alarms
48853 Integer High byte - Feeder 1 status
or hex Bit 0 – Feeder interlocked stopped
Bit 1 – Feeder interlocked started
Bit 2 – Positive control deviation (HGC-type only)
Bit 3 – Negative control deviation (HGC-type only)
Bit 4 – Started
Bit 5 – Alarm
Bit 6 – Refill (HCN-type); Auto tare (G-type); Discharge (A-type)
Bit 7 – Alarm indication
Low byte - Feeder 1 status(continued)
Bit 0 – Feeder is coarse/ramp feeding (NA-type only)
Bit 1 – Feeder is fine feeding (NA-type only)
Bit 2 – Batch end (NA-type only)
Bit 3 – Tolerance check (NA-type only)
Bit 4 – Start delay time runs down (HGC-type only)
Bit 5 – Stop delay time runs down (HGC-type only)
Bit 6 – Anti vibration (HGC-type);
Batch stabilization time (NA-type)
Bit 7 – Material stabilization time
48854 Not used
48855 Integer Feeder 2 status
or hex
48856 Not used


No.
177 48857 Integer Feeder 3 status
(cont’d) or hex
48858 Not used
or hex
48860 Not used
or hex
48864 Not used
or hex
48866 Not used
or hex
48868 Not used
or hex
48870 Not used


No.
178 Feeder status and Alarms (HGC-type only)
80h – Read
or hex
48904 Not used
or hex
48906 Not used
or hex
48908 Not used
or hex
48910 Not used
or hex
48914 Not used
or hex
48916 Not used
or hex
48918 Not used
or hex
48920 Not used

3. Read communication status
The following table details the addresses of the communication status between the DL-4000 and the Congrav L/M-3.
This data is in the DL-4000 and can be accessed by the PLC to ensure reliability of the communication.
Read communication status

Address Format Description
40001 Integer High byte Not used
or hex Low byte Bit 0 – NAK error
Bit 1 – Timeout error
Bit 2 – Unexpected character error
Bit 3 – Not used
Bit 4 – Not used
Bit 5 – Not used
Bit 6 – Not used
Bit 7 – Communication error
40002 Integer Counter for the NAK errors
or hex
40003 Integer Counter for the Timeout errors
or hex
40004 Integer Counter for the unexpected characters errors
or hex
40005 Integer Counter for the No. Of messages sent to Congrav L/M-3
or hex
40006 Integer Counter for more than three successive errors of any kind – sets
or hex the communication error bit
Note:
The data is byte swapped; i.e. low byte is actually the high byte and vice versa. Therefore the PLC application
should swap the bytes before using the values in the application.

B. DATALINK Configuration
For most application the unit comes pre-configured with the appropriate data so that it is ready to “plug and play”. However for
those applications where this data is not available or was corrupted for whatever reason the following is the description of the
values required in the configuration, using the DataLink standard configuration software “DL32-4000” (ver 2.03 or later), which
is supplied with the unit.
A. Start the configuration program and select the following:
1. On the Main Menu click on the DL4000 ALL MODELS button.
2. Choose the DL4000 Model used by clicking on the DL4000-BTI button.
3. Select which COM port on the PC the DL4000 is connected to by clicking on the appropriate ‘Radio’ button. COM1 is
most commonly used, however COM2, COM3 and COM4 are also available.
4. Select operation you want to perform and follow instructions further below:
a) For preparing a new configuration file click on the Configure/Open File button.
b) To download to the DL-4000 an existing configuration file on the PC click on the Download from FILE button.
c) To upload the existing DL-4000 configuration to a file on the PC click on the Upload to FILE button.
B. To configure a new configuration (button in 4.a. above) select the following:
1. Choose Newtork protocol for CHA by clicking on the appropriate ‘Radio’ button. Modbus (should be selected in this
case) or DF1 are available.
2. Select communication speed (Baud rate) and station number with the appropriate drop down menus. Speed should be the
same as set on the Modbus host. Station number should be 1, unless otherwise required.
3. View and change as appropriate the communication parameters to correspond to the Modbus host. Selections are made by
clicking on the appropriate ‘Radio’ button.
4. Select communication speed (Baud rate) for the Congrav L/M-3 with the appropriate drop down menu. Speed can be either
one of the following three: 9600, 19.2 or 38.4 as selected on the Congrav.
5. Select Congrav type connected to the DL-4000. L/M3 in this case. Selection is made by clicking on the appropriate
‘Radio’ button.
6. View and change as appropriate the communication parameters. Selections are made by clicking on the appropriate ‘Radio’
button. Parameters should be as follows:
PARITY YES
PARITY EVEN
DATA BITS 8
STOP BITS 1
HANDSHAKING IGNORE
SERIAL CONNECTION RS422-4 Wire
7. Save the configuration with the following:
a) Click on the CONFIGURATION Settings button
b) Select Save DataLink Configuration Settings… from the pull down menu.
c) Use the ‘Save As’ explorer type window to select the folder and enter the desired file name.
8. Return to previous menu by clicking on the RETURN to Main Menu button.
C. To download an existing configuration (button in A.4.b. above) select the following:
1. Click on the DOWNLOAD CONFIGURATION FILE TO A DATALINK button.
2. Use the ‘Open’ explorer type window to select the folder and file name as entered in A.7.c. above or as previously saved.
3. Follow the on-screen prompt and press the ‘Configure’ pushbutton on the DataLink unit (only the CHA and CHC lights
should be red and the Power light green).
4. Follow the on-screen prompt and press the ‘Reset’ pushbutton on the DataLink unit to put it ON-LINE.
5. After verifying that the ‘STATUS’ line includes the A-OK message, return to previous menu by clicking on the RETURN
to Main Menu button.
D. To upload an existing configuration (button in A.4.c. above) select the following:
1. Click on the UPLOAD button.
2. Follow the on-screen prompt and press the ‘Configure’ pushbutton on the DataLink unit (only the CHA and CHC lights
should be red and the Power light green).
3. Use the ‘Save As’ explorer type window to select the folder and enter the desired file name.
4. Verify that the ‘STATUS’ line includes the A-OK message.
5. View and change as appropriate the configuration by clicking on the VIEW button and following instructions in B. above.
6. When done, return to previous menu by clicking on the RETURN to Main Menu button.

C. HONEYWELL Addendum
To establish communication between the DataLink DL-4000 and the Honeywell TDC-3000, array points have to be built in
the SI FTA of the Honeywell TDC-3000. The Honeywell TDC-3000 has the following restrictions for the arrays:
1. Each array can contain data of one type only (i.e. integer or floating point).
2. Each array has a base address, and depending on the data type a maximum number of elements: 16 for floating point
data and 32 for integers.
3. The maximum number of arrays that can be built in an SI FTA is 16.
To help overcome the restrictions, the following improvements in the DataLink DL-4000 were made:
1. Certain flags (total of 20) in one “command” with base address at 40600.
2. Production parameters (total of 24 floating point values) in two “commands” with base address at 45000.
The memory map (addressing) for the modifications are in the following tables, which should be regarded as an addendum
to the regular memory map – as detailed in Appendix A.

Write data to Congrav L/M

No.
100 Production parameters for feeder 1 (command #80)
Production parameters for feeder 2 (command #81)

Write data to Congrav L/M

No.

Read data from Congrav L/M

No.
12 Various Read Flags for commands
40600 Integer Feeder preselection (command No. 4) -
or hex Read flag
0 – No read
80h – Read
40601 Integer Start conditions and Feeder modes (command No. 5) – Read flag
or hex
40602 Same Production parameters for feeder 1 (command No. 80) – Read flag
40610 Same Group set-points and actual values (command No. 143) – Read flag
40611 Same Feeder 1 set-points and actual values (command No. 144) – Read flag
40619 Same Feeder status and Alarms (command No. 177) – Read flag

Note: Flags for the following data should be set in either command No. 12 or the appropriate command No.

No.

Note: Flags for the following data should be set in either command No. 12 or the appropriate command No.

No.

DataLink DL-4000 Manual - Congrav LM3 To Modbus

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DATALINK

DL-4000 COMMUNICATION CONTROLLER

Rev: 1.03 Sep 10, 2010

DL-4000 VERSION: 1.10 or higher

Rev 1.03 Sep, 2010 Supersedes: Rev 1.02 PAGE 3

2. DATALINK SPECIFICATIONS FOR CONGRAV L/M-3 INTERFACE

Rev 1.03 Sep, 2010 Supersedes: Rev 1.02 PAGE 4

3.1 DL-4000 to Congrav L/M-3 Connection

DL-4000 Congrav L/M-3

3.2 DL-4000 to Modbus Host Connection

1 (TX-) RS-485 RX-

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4.1 Communication with Modbus

4.2 Communication with Congrav L/M-3

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5. USE OF THE DL-4000 COMMUNICATION CONTROLLER

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6. SAMPLE APPLICATION – READ AND WRITE SETPOINT

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Register Data Function

Register Data Function

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Register Data Function

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Register Data Function

Register Data Function

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Register Data Function

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A. Modbus Addressing in DL-4000

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1. Write data to Congrav L/M-3

Write data to Congrav L/M-3

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Write data to Congrav L/M-3

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Write data to Congrav L/M-3

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Write data to Congrav L/M-3

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Write data to Congrav L/M-3

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Write data to Congrav L/M-3

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Write data to Congrav L/M-3

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Write data to Congrav L/M-3

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Write data to Congrav L/M-3

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Write data to Congrav L/M-3

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Write data to Congrav L/M-3