Pro face connection to Mitsubishi DIASYS Netmation

Pro face Connection Mitsubishi DIASYS Nettation: MODBUS TCP Communication Configuration and Troubleshooting Complete Guide

In modern industrial automation systems, reliable communication between human-machine interface (HMI) and programmable logic controller (PLC) is the core to achieve process monitoring and control. Mitsubishi Heavy Industries, Ltd.'s DIASYS Nettation system, as a high-performance process control platform, is often used in conjunction with the Pro face series human-machine interface. This article is aimed at on-site engineers and system integrators, detailing the complete process of establishing communication between Pro face and DIASYS Netmation through MODBUS TCP protocol, including system topology selection, parameter configuration, address mapping, redundant CPU processing, and common error troubleshooting, to help you quickly complete project deployment and solve communication failures during operation.

System configuration and network topology selection

The Pro face human-machine interface and Netmation CPU support multiple network connection methods to meet the needs of control systems of different scales. Before starting the configuration, it is necessary to select a suitable topology based on the actual structure on site. All connections are based on Ethernet (TCP/IP), and the Netmation system follows the MODBUS TCP specification, so this driver does not support GP-4100 series monochrome models.

1.1 Connection method for single CPU system

When there is only one Netmation CPU in the system, the following topology can be used:

1: 1 Connection: A Pro face is directly connected to a Netmation CPU. This is the simplest structure, suitable for single machine equipment or small sections.

1: N-connection: One Pro face communicates with multiple Netmation CPUs simultaneously. For example, a central monitoring station needs to read data from multiple decentralized controllers.

n: 1 Connection: Multiple Pro faces access the same Netmation CPU. Commonly used for multiple operator stations to monitor the same large-scale process.

n: M-connection: Multiple Pro faces and multiple Netmation CPUs form a mesh communication. Suitable for complex production lines with multiple control areas and independent operation stations in each area.

1.2 Connection method of dual redundant CPU system

The Netmation system supports CPU redundancy configuration to improve availability. In a dual CPU architecture, the primary CPU and secondary CPU run synchronously, and in the event of a primary CPU failure, the secondary CPU automatically takes over. The Pro face driver has specifically designed a control mode detection mechanism for this purpose.

1: 1 Connection: Connect one Pro face to a pair of redundant CPUs. By configuring the 'Control State Storage Address', Pro face can detect which CPU is in the master control state every second and automatically switch communication targets.

1: N-connection: One Pro face connects multiple pairs of redundant CPUs. IP addresses and control mode detection addresses need to be specified separately for each pair of CPU's primary and backup instances in the device settings.

n: 1/n: m hybrid connection: suitable for scenarios with multiple HMIs and multiple pairs of redundant CPUs. Reasonable planning of communication load and redundant switching logic for each HMI is required in the project.

Engineering suggestion: Regardless of the topology used, IP address conflicts should be avoided, and the IP addresses of all Ethernet nodes (including Pro face, Netmation CPU, switches, etc.) must be in the same subnet and unique. When connecting a dual redundant system, it is necessary to configure the control state storage address (such as CDO0001) in the Netmation dedicated software, otherwise Pro face will not be able to correctly recognize the current active CPU.

External device selection and driver configuration

In the Pro face programming software GP Pro EX, it is necessary to correctly select the external device type to enable the corresponding communication protocol.

2.1 Equipment selection steps

Open the GP Pro EX project and enter the 'System Settings' window.

Click on 'Device/PLC Settings' to add a new device to the device list.

Select 'Mitsubishi Heavy Industries' from the' Manufacturer 'dropdown menu.

Select 'DIASYS Netmation MODBUS TCP' from the 'Driver' dropdown menu.

2.2 System Area Usage Options

This driver provides a 'Use System Area' option. After activation, the Pro face system data area (LS area) will synchronize with the specified device address in Netmation. With this feature, engineers can switch HMI display screens, pop up alarm windows, or write values by modifying specific addresses in Netmation's ladder diagram program, achieving deep integration of HMI and PLC control logic. The specific setting method of the system area can refer to the "LS Area (Direct Access Mode Area)" chapter in the GP Pro EX reference manual.

2.3 Port selection

Some models of Pro face offer multiple Ethernet interfaces. Please specify the actual port connected to Netmation (such as LAN1, LAN2) in the settings. This setting can also be modified in HMI offline mode.

Example of Communication Parameter Setting

A complete communication configuration needs to be completed simultaneously on both the GP Pro EX project and Netmation side. Taking a typical single CPU connection as an example.

3.1 Communication Settings in GP Pro EX

Select the Netmation device that has been added in the [Device/PLC Settings], click the "Settings" button to enter the detailed configuration interface:

Port number: The TCP port on which Pro face listens for local communication. The default is 59710, and the adjustable range is 1024~65535. This port must match the remote port configured on the Netmation side.

Timeout: The maximum time that HMI waits for Netmation response, in seconds, ranging from 1 to 127. Suggest setting it to 3-10 seconds based on network load. Being too short may result in false alarms and timeout errors; If it is too long, the fault detection will be delayed.

Retry count: The number of times HMI resends commands when Netmation is unresponsive, ranging from 0 to 255. Usually set to 2-5 times.

Sending waiting time: The number of milliseconds that HMI delays sending the next command after receiving the previous data packet, ranging from 0 to 255. Appropriately increasing (such as 10ms) in slower networks can reduce conflicts.

3.2 Device Specific Settings (Netmation CPU Parameters)

In the device specific settings area, it is necessary to fill in the communication parameters of the Netmation CPU:

IP address: The IP address of the Netmation CPU. The range is 0.0.0.0~255.255.255.255. Note: If the IP address is not in the format of 192.168.xxx.xxx, the system will display a prompt message but will not report an error. It is recommended to use a planned and unified private address segment (such as 192.168.1.10) in the project.

Port number: The port number of the MODBUS TCP service on the Netmation CPU, ranging from 1 to 65535. The initial value is 59710, which should be consistent with the local port number of Pro face.

CPU redundancy: If a dual CPU redundant system is used on site, check this checkbox. After checking, the "Check Control Mode" field in the main CPU settings and backup CPU settings becomes editable.

Check control mode: When redundancy is enabled, a Netmation device address (such as CDO0001) must be specified here. Pro face will send a read command to this address every second to determine which CPU is currently in the master state. This address must be the same as the control state storage address configured on the Netmation side.

Double byte order: Used for the transmission order of 32-bit data (such as double byte integers). You can choose "low letter first" or "high letter first", which must be consistent with the data format of Netmation. The default is usually 'Little Endian'.

3.3 Netmation side settings

Use Netmation specialized software (such as DIASYS Netmation Engineering Tool) to configure the following items:

The IP address of the CPU must be consistent with the IP address set in GP Pro EX.

MODBUS TCP port number: usually 59710, or a custom value.

Control state storage address: an address used for dual redundant systems (such as CDO0001). This address is automatically updated by the Netmation system and indicates the current main CPU.

Important note: The IP address of the HMI itself cannot be set in the GP Pro EX project and needs to be completed through screen touch in offline mode of the Pro face device. Make sure that the IP address of the HMI is on the same subnet as the Netmation CPU and does not conflict.

Supported device addresses and mapping rules

The Pro face driver supports reading and writing four types of data in Netmation: digital output, digital input, analog output, and analog input. However, please note that Analog Input (CAI) and Analog Output (CAO) are read-only on the Netmation side (i.e. HMI cannot write CAO, only read it).

4.1 Address Range

Device bit address range, word address range, 32-bit support for read and write properties

CDO (Digital Output) CDO0001- CDO8000 CDO0001- CDO7985 L/H-18+1 read-write

CDI (Digital Input) CDI0001- CDI8000 CDI0001- CDI7985 L/H-18+1 Read Only

CAO (Analog Output) - CAO0001- CAO4000- Read Only (Note 1)

CAI (Analog Input) - CAI0001- CAI4000- Read Only

Note 1: Although the manual marks CAO as write disabled, in actual projects, please refer to the specific version of the Netmann system, as write may be supported in some cases.

4.2 Equipment Code and Address Code

When using the "device type and address" method to specify a data source in the Pro face screen (for example, numerical display components need to be associated with a PLC address), device code (hexadecimal) and address code are required.

Equipment Name Equipment Code (HEX) Address Code Calculation Formula

Digital output CDO 0080 (Address -1)/16

Digital input CDI 0081 (Address -1)/16

Analog output CAO 0000 word address -1

Analog input CAI 0001 word address -1

For example, to access CDO address 0005, first calculate (5-1)/16=0.25 and round it down? The actual address code should be divisible according to the manual formula. A simpler understanding: bit address CDO0001 corresponds to address code 0, CDO0017 corresponds to address code 1, and so on. For CAI0005, address code=5-1=4.

4.3 System Data Area (LS Area)

The system data area (LS area) of Pro face can also be mapped to the aforementioned device addresses of Netmann. Efficient state exchange between HMI and PLC can be achieved through system area settings. Please refer to the GP Pro EX reference manual for specific LS area address allocation.

Error Messages and Troubleshooting Guide

Communication failure is the most common issue on site. Pro face will display a formatted error message on the screen: 'Number: Device Name: Error Message (Error Occurrence Area)'. Understanding this information is the key to quickly solving problems.

5.1 Error Display Format

Number: Error code.

Device Name: The name set for the external device in GP Pro EX, which defaults to PLC1.

Error message: A textual description of the error.

Error occurrence area: It may be an IP address (displayed as "IP address (decimal): MAC address (hexadecimal)"), device address (such as "Address: CDO0001"), or error code received from Netmation (such as "Error Code: 1 [01]").

5.2 PLC specific error codes

When Pro face sends a command to Netmation, Netmation may return the following standard MODBUS exception code:

Error code (decimal) reason common trigger message

01 unsupported function codes RHxx034/RHxx035

02 Address does not exist or exceeds the range RHxx036/RHxx037

03 Data value not accepted (such as writing illegal value) RHxx034/RHxx035

Troubleshooting steps:

For error 01: Check if MODBUS function codes that Netmation does not support are used in GP Pro EX (such as some variations of batch write hold registers). Try using single character reading and writing instead.

For error 02: Confirm if the device address being accessed (such as CDO9000) is within the valid range of Netmation. Refer to the Netmation manual to verify address limits.

For error 03: Check if the data type written is correct (such as writing a hexadecimal value to a numeric address), or if the value is out of range.

5.3 Unique Error Messages

The following error message only appears in the DIASYS Netmation MODBUS TCP driver and is strongly related to redundant CPU configuration:

RHxx128：There is two primary CPU

Pro face detected two CPUs claiming to be in the main control state simultaneously. This is usually due to inconsistent Netmation redundancy configurations or network partitioning. Solution: Check the synchronization link of the redundant CPU, restart the backup CPU or reconfigure the redundant parameters.

RHxx129：There is not primary CPU

Indicates that no main CPU has been detected. Possible reasons: Both CPUs are in a faulty or offline state, or the control state detection address (CDOxxxx) is configured incorrectly. Firstly, confirm the CPU status indicator light on the Netmation side, and then check if the "Check Control Mode" address set in Pro face matches the actual control status address in Netmation.

RHxx130：This project data has too many nodes

In the current project, Pro face is attempting to establish connections with over 16 Neumann nodes simultaneously. This driver supports up to 16 concurrent connections. Please reduce the number of devices or re plan the network grouping.

5.4 General Communication Troubleshooting Process

Physical connection check: Is the Ethernet cable properly plugged in? Is the switch powered on? Is the corresponding port indicator light flashing?

IP address verification: Check its IP address in HMI offline mode and use PC ping to test whether the IP and Netmation CPU IP are reachable.

Port reachability: Use MODBUS scanning tools (such as ModScan) to test if Netmann's TCP port (default 59710) is open.

Configuration consistency: Ensure that the IP, port number, timeout, and other parameters in Pro face match exactly with the Netmation side. Please note that in redundant mode, the IP addresses of the primary and backup CPUs cannot be reversed.

Log analysis: Some Pro face models support exporting communication logs, which can further locate errors.

Engineering Practice Suggestions

To ensure long-term stable operation of the system, please follow the following additional recommendations:

IP address planning: Static IP addresses are uniformly allocated by network administrators and recorded. Avoid using automatic access control (DHCP).

Redundant CPU status monitoring: In addition to Pro face automatic monitoring, it is recommended to display the current status of the active CPU on the HMI screen (for example, by reading the control status address and reflecting it in the indicator light element), to facilitate the operator's understanding of the system health.

Connection limit: Each Pro face can connect up to 16 Netmann nodes simultaneously. If a project requires monitoring more than 16 CPUs, consider increasing the number of HMIs or using data gateway aggregation.

Firmware version compatibility: Before first use, confirm that the Pro face firmware version and GP Pro EX version support the driver (refer to the official release instructions).

Offline mode debugging: After completing the basic settings in GP Pro EX, download the project to HMI, and then enter offline mode to check the communication parameters again - modifications in offline mode will overwrite the project settings, which is an effective means of quickly correcting errors on site.

Regularly check the number of EEPROM writes: Although this driver does not directly involve the internal EEPROM of HMI, the storage medium of Netmation CPU has a write life. Frequent writing of CDO and other addresses may accelerate aging, and data refresh cycles should be planned reasonably.