Atlas Copco Airpower NV AIRCONTACTQB GSM Modem User Manual AirContact Handbook V16

Atlas Copco Airpower NV GSM Modem AirContact Handbook V16

User Manual

1ELEKTRONIKON® MKIV AIR CONTACT GSM quad-band modem Part.Nr. 1900 0711 XX (78-80) Hardware Manual Version 1.6 The version of the entire document is increased on the occasion of each modification. Modifications are listed in the chapter “Version History“.
Air Contact Hardware Manual 2 All rights reserved. This document remains the intellectual property of ATLAS COPCO. No part of this document may be reproduced, transmitted, transcribed, stored in a retrieval system, in any form or by any means, electronic, mechanical, optical, manual or otherwise, without permission in writing of ATLAS COPCO. Transmission on to third parties is only allowed if the explicit permission of ATLAS COPCO is obtained before hand. ATLAS COPCO declines all claims for damages which arises from the application of information that may be wrong or inadequate or missing in this document. ATLAS COPCO reserves the right to change this document complete or partially . All brand names and product names are trade marks or registered trade marks of the proprietors of the respective titles. IMPORTANT REMARKS Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. Symbols for attention notes Warning for general dangers. Warning for dangerous electrical voltage. ESD endangered devices. Housings and connections are only to be opened from trained persons! Remarks.
Air Contact Hardware Manual 3 Table of contents Page 1 Introduction 4 1.1 Preface 4 1.2 Product Description 4 1.3 FCC 4 1.4 IC 5 2 Glossary 6 3 Features 7 4 Function Description 8 4.1 General 8 4.2 Digital Input 8 4.3 HMI 8 4.4 Nonvolatile RAM functionality 9 4.5 CAN-Bus 9 4.6 RS232 10 4.7 GSM Modem 10 5 Microcontroller 11 5.1 Block diagram 12 5.2 Memory-Layout 13 6 GSM components 15 6.1 GSM modem module 15 6.2 Antenna 15 7 Technical Data 16 8 Pin Assignment 18 9 Housing 20 9.1 Front View 20 9.2 Views 21 9.3 The GSM module location 22 9.4 The antenna placement 22 10 Battery Replacement 23 11 IMEI code 24 12 General Operation 25 13 Versions history 26
Air Contact Hardware Manual 4 1 Introduction 1.1 Preface This manual gives all the main information relevant the Air Contact module for Atlas Copco compressors. It provides also preliminary hardware information for the system programmer. The manual contains interconnections, technical data and mounting requirements. 1.2 Product Description This manual describes the main part of the AIR CONTACT modem GSM module. The main features of the product are the following: 1. send some diagnostic SMS message to GSM telephone network on digital input events. 2. establish a data modem connection over the GSM network. 3. send a special diagnostic SMS message in case of loss of main power. 4. send a special diagnostic SMS message in case of backup battery replacement service 1.3 FCC NOTICE: This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions (1) this device may not cause harmful interference and (2) this device must accept any interference received, including interference that may cause undesired operation. NOTICE: Changes or modifications made to this equipment not expressly approved by Atlas Copco may void the FCC authorization to operate this equipment. NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: • Reorient or relocate the receiving antenna. • Increase the separation between the equipment and receiver. • Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. • Consult the dealer or an experienced radio/TV technician for help. IMPORTANT NOTE: FCC Radiation Exposure Statement: This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with minimum distance of 20cm between the radiator and your body. This transmitter must not be co-located or operating in conjunction with any other antenna or transmitter.
Air Contact Hardware Manual 5 1.4 IC NOTICE: This Class A digital apparatus complies with Canadian ICES-003. Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.
Air Contact Hardware Manual 6 2 Glossary ELEKTRONIKON® MkIV Compressor control electronic of the fourth generation. CPU Control Process Unit. PCB Printed Circuit Board HMI Human Machine Interface Main Controller Main control part of each compressor. Contains MMI, I/O’s IC Integrated circuit. EMC Electromagnetic Compatibility LED Light Emitting Diode Flash EPROM Erasable Programmable Read Only Memory. Flash types allows an electronic erase. SRAM Static Random Access Memory
Air Contact Hardware Manual 7 3 Features Main Parts • HMI o 2 x 7-segment LED display o 1 push button o 1 Service hours rotary switch with 10 positions o status LEDs o 1 x CAN address dip switch • 512 kByte Flash EPROM • 128 kByte SRAM • 1 kbytes E2PROM emulated in a 8Kbytes Flash sector • 1 RS232 serial Line • 1 CAN BUS serial line (not optocoupled) • Digital Inputs to be connected to a free contact • Antenna with magnetic base, 5m coaxial cable, SMA right angle connector • 1 GSM quad-band AT modem with rechargeable LI-ION battery. Power Supply: wide range voltage (100 ÷ 240 VAC)
Air Contact Hardware Manual 8 4 Function Description 4.1 General The Main Controller is supplied with nominal 115/230 VAC. The device has not a fuse in the power supply line. A fuse T1AH, 250V (slow-blow) CSA certified and UL recognized has to be provided externally as described in paragraph 10.1. Warning, dangerous electrical voltage can be at the connector. Never touch connections, when the device is running. Protective earth PE has to be connected. The Main Controller contain electrostatically sensitive components: Prior to assembly and service operations, the personnel must be free of electrostatic charge, e.g. by touching the PE fixing screw or other grounded metal surfaces in the control cabinet. 4.2 Digital Input The controller supplies a ground, which could be returned to a digital input over an external voltage free contact.. • Note, that the digital inputs are not isolated. • When relay contacts are used, they generate typical 20ms bounces. The filtering of these signals has been done in software. 4.3 HMI The HMI (Human Machine Interface) consist of: • 2 x 7-segment LED display • 1 push button • 3 LEDs • 1 x selector rotary dip switch • accessible SIM card holder • Customer specific adhesive lexan front foil 4.3.1 LED - Display The LED-display provided for the Air Contact is a simple 2 digit 7-segment LED. It is used mainly to show the time left in service hours. One digit is for the thousands of hours and the other one for the hundreds of hours. Some other diagnostic numeric codes could be also showed. Parameter Value dimensions 16 x 26 mm Digits 2 x 7segment Color Red Led Segments
Air Contact Hardware Manual 9 4.3.2 Push button The module has 1 push button. It is mechanically protected from accidental pushing. It is used to reset the service hours counter. 4.3.3 Leds Three LEDs are mounted on the PCB, visible to the operator through dedicated holes in the front panel and have the function to indicate machine status. One LED is controlled by microcontroller, one LED is directly controlled by modem AT interface and one LED is used to indicate power on. 4.3.4 Switches One rotary selector switch with 10 positions is provided in the design to adjust the service time hours. The switch is accessible from outside and can be turned with a screw driver. Service Time hours from 1000 up to 9000 are possible. The switch is used to select the thousands of hours. 4.3.5 Sim Card Holder A SIM card holder is provided in the design to insert and change the SIM card. The SIM card holder is accessible from outside the front panel under a plastic cap removable by service personnel. 4.3.6 Lexan adhesive front foil A coulored custom specific adhesive front foil in Lexan material is provided on the front panel to show connectors code and labels indication. 4.4 Nonvolatile RAM functionality Like the Main MkIV Controllers the Air Contact GSM module has an Nonvolatile RAM feature to save data before a power off occurs. The concept behind is the same. If the power supply falls below the specified minimum voltage an interrupt occurs. From now on the CPU saves the specific data in the Flash EPROM. 4.5 CAN-Bus The C164CI has an integrated On-Chip CAN unit according the CAN specification V2.0 part B. This module handles the completely autonomous transmission and reception of CAN telegrams. That means, once the transmit buffer has written or the receive buffer is empty no CPU time is required. The CAN unit can receive and transmit standard frames with 11-bit identifier as well as extended frames with 29-bit identifier. Which kind of configuration will be used depends on the software protocol. The baudrate is programmable in a wide range, but only standards will be implemented. Switches: One 8 dip switch selector is provided in the design to set the CAN-Bus node number. The switches are accessible from outside. Node numbers from 1 up to 31 are possible.
Air Contact Hardware Manual 10 8 x Dip Switch CANbus Node Address Note: the address dip switch is read only at power on of the supply Example of address selection: CANbus Node Address = 1, the Dip switch configuration is: 4.6 RS232 This interface is useful for point to point communication at low speed. The signals are referred to ground. In Air Contact configuration the externally accessible RS232C serial is used to connect directly to Modem serial interface. • The pin assignment is compatible with a DCE connection • RS232C is not suitable for high speed and long distance. • hardware handshake is provided. An internal electronic switch is used to connect alternalively the Modem serial connection to microcontroller serial port (referenced as PORT1) or to the DB9 connector serial port (referenced as PORT2). 4.7 GSM Modem A mountable on PCB commercial modem module is used to integrate a GSM telephone connection to the electronic stand alone controller. The antenna is external. Dip Swich Number Function 1,2,3 Reserved to Modem functionality 4,5,6,7,8 LAN address selector (Binary Code, valid = 1 to 31) Dip Sw number 1 2 3 4 5 6 7 8 ON x OFF x x x x x x x
Air Contact Hardware Manual 11 5 Microcontroller The design of the Air Contact is a typical embedded control application that demands for the usage of a microcontroller. The choosen microcontroller should fulfil following requirements: • high level system integration • eliminate the need for additional peripheral devices • provide system security and fail-safe mechanisms • provide effective means to control and reduce the power consumption For this reason the Infineon C164CI microcontroller is chosen. This microcontroller is a member of the successful 166-family. The 166-family are 16-bit oriented microcontrollers that offer a wide range of different types beginning from a small low cost up to a high integrated type. This family of microcontrollers was also distributed by ST Thomson but not all types are available from them. The fact that these microcontrollers are used in different industrial and automotive applications as well makes possible that a lot of software and development tools are available on the market. The Infineon microcontroller C164CI has following basic feature: • High performance 16-bit CPU core • Control oriented instruction set with high efficiency (bit, byte and word data types) • Internal 2kByte RAM • External bus interface (8-bit in the ELEKTRONIKON® MkIV application) • flexible interrupt system with different priority levels • 10-bit A/D converter • CAN controller • Asynchronous Serial Interface • Synchronous Serial Interface • Watchdog • General purpose timer unit • I/O lines with individual bit addressability • internal PLL The Infineon microcontroller C164CI is the core component in the Main Controller design. Around the C164CI external RAM, Flash EPROM, LCD-Display, I/O’s and all communication interfaces (CAN-Bus, RS485, I2C-Bus) are provided. For all Main Controller the identical fundamental core design is used and they differ only in the peripherals.
Air Contact Hardware Manual 12 5.1 Block diagram Power supply Voltage control (power-fail) 4 digital inputs 1 push button 3 status LEDs Control Unit Core C166 CAN Controller Digital I/O interface RAM FLASHClock Unit DB9 CAN Serial ControllerDB9 RS232 GSM Modem AT GSM Modem AT SMA Antenna connector Service Time selector CAN address selector Serial Switch Port 1Port 2 Serial AT protocol Rechargeable Battery 5MHz µController SIM Card
Air Contact Hardware Manual 13 5.2 Memory-Layout The Siemens microcontroller C164CI is configured so that up to 1MByte external, linear memory is addressable. Code and data are accessed in the same address space. The C164CI has internal • 2 kByte RAM • Special Function Register area The internal and the external memory area are mapped into common address space. For more information refer to the Siemens data book. The table below shows the external memory configuration. The memory is 8-Bit oriented. External 8-Bit Memory Organisation Address MSB Memory LSB possible device sizes FFFFFh FF000h Reserved FEFFFh E0000h SRAM AREA 124k x 8 not accesable DFFFFh 80000h FLASH AREA 896k x 8 7FFFFh 40000h 512k x 8 3FFFFh 256k x 8 00000h Default configuration for the memory is 512kByte Flash and 124kByte SRAM, optionally the 1024kByte flash could be also mounted.
Air Contact Hardware Manual 14 5.2.2 Flash EPROM For code memory a Flash EPROM is provided. Flash EPROM’s have the property that they are in circuit programmable. This allows to program the controller without opening it and making it easy field updates. Following device sizes are provided in the controller design: • 256 kByte Typ: 29F200 • 512 kByte Typ: 29F400 • 1024 kByte Typ: 29F800 This two types are called bottom boot sector Flash EPROM because they consist 1x16kByte, 2x8kByte, 1x32kByte and the rest are 64kByte sectors. To provide that three different types of Flash EPROM on the PCB do not cause additional costs and allows to adapt the right size. Which type will be used will be decided during the project and it depends on device costs and size of application software. Technical data sector erase time 1) typ. 1 s chip erase time 1) typ. 8 s byte programming time 1) typ. 7 µs chip programming time 1) typ. 3.6 s access time read cycle typ. 250 ns 1) The data above specifies only the time required from the Flash EPROM. For a complete software download the time to transfer the data (baudrate), handshaking and check sum control should be added. The whole downloading time depends on the software concept too. • Flash EPROM has a limited number of program/erase cycles per sector. It is not suitable for data memory that are updated every PLC cycle. The manufacturers of this devices guarantees the minimum of 1 million program/erase cycles. • Flash EPROM allows only an erase operation for a whole sector (16kByte or 64kByte) and not for a byte. • the program sequence for the Flash EPROM depends on manufacturer. The software must support different types. • To the Flash EPROM only 16 Bit access (word) is allowed. 5.2.3 SRAM The SRAM (Static RAM) is provided as data memory. Of course it could be used also as code memory with the C164CI microcontroller. 128 kByte only 124 kByte useable Technical data access time read/write typ. 250 ns The data bus to the SRAM is 8 Bit wide.
Air Contact Hardware Manual 15 6 GSM components 6.1 GSM modem module The Quad-band GSM modem is the Wavecom Wismo Quick Q24CL001. It is a self-contained GSM 850/900/1800/1900 quad-band module including following features:  2 watts GSM 850 radio section running under 3.6 volts  2 watts GSM 900 radio section running under 3.6 volts  1 watt GSM 1800 radio section running under 3.6 volts  1 watt GSM 1900 radio section running under 3.6 volts  Digital section running under 2.8 volts  1.8/3V only SIM interface  Real time clock with calendar  Battery charge management  Echo cancellation + noise reduction  Full GSM software stack  Complete shielding  Complete interfacing through a 60-pin GPC connector: o Power supply o Serial link o SIM card interface  RF connection pads ( to the antenna) 6.1.1 RF functionalities The radio frequency part is based on specific quad-band chip including:  Low – IF receiver  Quad RF synthesizer  Digital IF to Baseband Converter  Offset PLL transmitter  One logarithmic Power Amplifier module  Quad-band Power amplifier module 6.1.2 Baseband functionalities The digital part is based on a Philips-VLSI chip (ONE C GSM Kernel). The chipset is using a 0.25micron mixed technology CMOS wich allow massive integration as well as low current consumption. 6.1.3 Applications The module is designed to be integrated into various types of applications such as handsets or vertical applications (telemetry, multimedia,..). For vertical applications, the internal firmware offers a set of AT commands to control the module. 6.2 Antenna The antenna has a magnetic base and it is prewired with 5 m of coaxial 50Ω cable. It is delivered with SMA male right angle connector. With this solution the extra depth necessary in front of the module to mount the antenna cable is less than 25 mm.
Air Contact Hardware Manual 16 7 Technical Data CPU-Core Parameter Value CPU Siemens C164CI-20MHz Address range 1 MByte CPU-Bus configuration 8/16 Bit Internal RAM 2 kByte Flash EPROM 512 kByte RAM 128 kByte Nonvolatile RAM 1 kByte CAN-Bus Parameter Value Controller Integrated in CPU Type /Specification Full CAN / BASIC CAN / V2.0 Part B Number of Nodes max. 32 Physical Layer ISO11898 Baudrate programmable Common Mode Rejection -2.....+7V Isolated no Connector Type Sub-D 9 pole male (according to CiA) RS232 Parameter Value Controller integrated in CPU Configuration half duplex Baudrate programmable Driver Output Voltage 0 Level 1 Level Output Level max. +5.0V....+15V (3kΩ to 7kΩ load) -5.0V.....-15V (3kΩ to 7kΩ load) ±25V (no load) Receiver Input Voltage 0 Level 1 Level Input Level max. +3.0V....+15V (3kΩ to 7kΩ load) -3.0V.....-15V (3kΩ to 7kΩ load) ±25V (no load) Isolated no Signals Handshake Hardware Connector Type Sub-D 9 pole female Display Parameter Value Type 7segment 2 digits Technology LED Viewing Area 16.2 x 26.7 mm Foil Material type Polyester PETP LED 3 x Green Keys 1 Rotary switch selector 1 Dip Switch selector 1
Air Contact Hardware Manual 17 Digital Inputs Parameter Value Number 4 Input Activation Connection to digital input ground through free relay contact Isolation No GSM modem Parameter Value Type GSM 850/900/1800/1900 quad-band Power Output 2 watt GSM 850/900 MHz 1 watt GSM 1800/1900 MHz SIM interface 1.8/3 Volt only SIM interface, fully compliant with GSM 11.11 specifications Software Fully GSM software Stack Antenna Specification 50 Ohms, coaxial cable, SMA connector RF performance Fully compliant with GSM 05.05 specifications Temperature range Operating: -20°C to +55°C Storage: -30°C to +85°C Supply From a dedicated LI-ION battery Battery Charger Internal Battery Life Time Typical from 2 to 3 years (*) (*) the worst case happens at high operating temperature General Parameter Value Supply Voltage Wide range voltage (100 ÷ 240 VAC) Power Consumption 10VA I max 0.15 A Type of Protection IP20 Temperature Range Operating Storage -10°C…..+55°C (*) -30°C…..+70°C Permissible Humidity Relative humidity 95% no condensation Noise emission EN 55022 class B: 1998 EN 50081-2: 1993 Noise immunity EN 50082-2: 1995 EN 61000-6-2: 1999 Weight 0.5 kg Dimensions ∼140x105x73mm (LxHxD) Housing Plastic Material - UL Flame Category: HB DIN RAIL (*)The Operating Temperature Range is limited to +55°C due of modem chip limits
Air Contact Hardware Manual 18 8 Pin Assignment Pin Assignment CAN-Bus (Lan) Sub-D 9 pole male 12X1 Pin Assignment RS232 Sub-D 9 pole female 12X15 Pin Assignment Digital Input 12X9 Male connector, straight, 5-way, pitch 3.5mm. Model: Wago 734-135 1 5 Pin Function 1 Digital Input 01 2 Digital Input 02 3 Digital Input 03 4 Digital Input 04 5 Digital Common Ground Pin Function 1 Reserved 2 CAN_LOW 3 CAN_GND 4 Reserved 5 Reserved 6 GND external supply 7 CAN_HIGH 8 Reserved 9 CAN external supply* * not used for MKIV Component. Supply for CAN-Driver already integrated 1 6 Pin Function 1 Reserved 2 RxD 3 TxD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 Reserved 1 6
Air Contact Hardware Manual 19 Pin Assignment 100÷240 VAC Supply 12X14 Male connector, straight, 3-way, pitch 5mm. Model: Wago 721-133 1 Pin Assignment Antenna Connector female connector Model: SMA Pin Function for 230VAC 1 100 ÷ 240VAC Supply 2 100 ÷ 240VAC Supply (N) 3 PE Pin Function 1 Ground 2 GSM RX/TX 1 2
Air Contact Hardware Manual 20 9 Housing 9.1 Front View RS232 connectorLAN connectorRemovable plastic cap over SIM holder, LAN address switch and battery location Antenna connectorLEDs digitsLEDs statusPush button Service Time rotary selector ConnectorSupply ConnectorInputs
Air Contact Hardware Manual 21 9.2 Views
Air Contact Hardware Manual 22 9.3 The GSM module location The GSM module can be located easily inside the cubicle mounted on a DIN-RAIL. This solution simplifies the housing of the module and the wiring (short wires). This arrangement suits a solution of an antenna cable connected at the housing of the GSM module with a SMA male connector. The cable will be allowed to come out the cubicle via a PG sleeve. Please refer to Air Contact Installation Manual. 9.4 The antenna placement This device has to be placed outside the compressor cubicle. This leads to the need of a cable to connect the antenna to module. The connection distance between antenna and module can also vary from case by case, and to be installed at the customer site. The chosen standard solution is an external antenna with magnetic base, prewired with 5 m cable and connected to the Air Contact via a male SMA right angle type connector.
Air Contact Hardware Manual 23 10 Battery Replacement The Lithium-ion battery used as backup supply power for the Chip GSM modem needs a replacement after some years of continous work. To execute this service replacement only when there is a really need a software algorithm will be implemented to evaluate the residual power capacity of the battery. The algorithm use a measure of the battery discharge time. When the battery is not recharging but the Air Contact is working it’s residual charge continuosly reduces. Measuring the speed of discharge and comparing it with a reference value then we can define an Event Level that can activate a warning status. In warning status a service replacement could be activated. The replacement is simple and could be executed without returning the module to the manufacturer. Following is a sequence of operations to replace the battery into the Air Contact box. 1. Unscrew the two screws on the rear of the module (figure 1) 2. Pull the left cap, pay many attention (figure 2) 3. Disconnect the battery connector (figure 3) 4. Replace and connect again the battery (figure 4) 5. Close the left cap (figure 2) 6. To fix the left cap screwing the two screws on the rear of the module (figure 1) Figure 1 Figure 2 Figure 3 Figure 4
Air Contact Hardware Manual 24 11 IMEI code The IMEI code it is placed on a label visible removing the left cap. It is also possible found it (together the part and serial number), on the document placed in the pack. Please pay attention to don’t loose the Aircontact code document.
Air Contact Hardware Manual 25 12 General Operation The RTS run time Codesys interface is installed in the Air Contact Firmware. With this software library a PLC application program could be downloaded through the CAN interface and simply executed at power on. A specific Codesys GSM library is developed to simplify management of the modem Chip. The Air Contact could work in two different modes: 1. SMS monitor 2. GSM modem In SMS monitor mode the digital inputs and some function events has the capability to send a dedicated SMS programmable text message to a specific dial GSM number. In GSM modem mode the serial AT protocol connection is directly accessible from the DB9-RS232 connector to an external device (PC, Airmonitor, other). For a detailed documentation on the software features of the Air Contact, please see the dedicated manual AirContact_User’s Manual.
Air Contact Hardware Manual 26 13 Versions history Version.: 1.0 Changes from 03.04.2006 Author: Maurizio Marmiroli Version.: 1.1 Changes from 03.04.2006 Author: Maurizio Marmiroli Version.: 1.2 Changes from 22.12.2006 Author: Maurizio Marmiroli Version.: 1.3 Changes from 02.02.2007 Author: Maurizio Marmiroli Version.: 1.4 Changes from 14.05.2007 Author: Claudio Guariso Version.: 1.5 Changes from 06.09.2007 Author: Amedeo Miletto Version.: 1.6 Changes from 17.04.2008 Author: Amedeo Miletto Author Checked Released Maurizio Marmiroli R&D Manager Doc.-Administrator Francesco Sgandurra Claudio Guariso
Air Contact Hardware Manual PRIMA ELECTRONICS Strada Carignano 48/2 Telephone Telefax AirContact_Handbook_V16.doc 10024 Moncalieri, Italy +39-011-68 27 211 +39-011-640 42 77 Copyright © 2008

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