Atlas Copco Airpower NV AIRCONTACTQB GSM Modem User Manual AirContact Handbook V16
Atlas Copco Airpower NV GSM Modem AirContact Handbook V16
User Manual
1
ELEKTRONIKON® 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
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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.
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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
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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.
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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.
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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
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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)
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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
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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.
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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
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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.
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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
FLASH
Clock Unit
DB9 CAN
Serial
Controller
DB9 RS232
GSM Modem
AT
GSM Modem
AT
SMA Antenna
connector
Service Time
selector
CAN
address
selector
Serial Switch
Port 1
Port 2 Serial AT protocol
Rechargeable
Battery
5MHz
µ
Controller
SIM
Card
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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.
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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.
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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.
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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
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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
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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
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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
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9 Housing
9.1 Front View
RS232
connector
LAN
connector
Removable plastic
cap over SIM holder,
LAN address switch
and battery location
Antenna
connector
LEDs digits
LEDs status
Push
button
Service Time
rotary selector
Connecto
r
Supply
Connecto
r
Inputs
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9.2 Views
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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
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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
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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.
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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.
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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
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