MPI AND PROFIBUS-DP DESIGN GUIDELINES by hnm46329

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									 Refrigeration Division
                                                                               Grasso



                                 MPI AND PROFIBUS-DP
                                  DESIGN GUIDELINES

                          Standard package with Piston Compressors
                                 Single Stage and Two Stage




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                                                                                                                                                        MPI AND PROFIBUS-DP
                                    Grasso                                                                                                                DESIGN GUIDELINES
Refrigeration Division




  1. System Arrangement ........................................................................................................................................................................... 5
  2. Signal Coupling MPI ............................................................................................................................................................................. 5
  3. Signal Coupling Profibus DP............................................................................................................................................................... 6
  4. Data word structure............................................................................................................................................................................ 6
  5. signal coupling Information............................................................................................................................................................... 7
  5.1 Received data...................................................................................................................................................................................... 7
     5.1.1 Control word in detail............................................................................................................................................................. 7
  5.2 Transmitted Data ............................................................................................................................................................................... 8
    5.2.1 Compressor 1.............................................................................................................................................................................. 8

  6. Alarm, Warning and status messages............................................................................................................................................. 9
  6.2 Compressor 1 ...................................................................................................................................................................................... 9
     6.1.1 Fault data word 1...................................................................................................................................................................... 9
      6.1.2 Fault data word 2...................................................................................................................................................................... 9
      6.1.3 Fault data word 3....................................................................................................................................................................10
      6.1.4 Fault data word 4....................................................................................................................................................................10
      6.1.5 Fault data word 5....................................................................................................................................................................11
      6.1.6 Warning data word 1............................................................................................................................................................11
      6.1.7 Warning data word 2............................................................................................................................................................12
      6.1.8 Warning data word 3............................................................................................................................................................12
      6.1.9 Status word 1 (compressor)...............................................................................................................................................13
      6.1.10 Status word 2 (compressor).............................................................................................................................................13
      6.1.11 Status word (unit)................................................................................................................................................................14

  7. Description of the in- and outputs................................................................................................................................................15
  7.1. Inputs ..................................................................................................................................................................................................15
     7.1.1 Potential free actuating commands from a master controller to the GSC ........................................................15
      7.1.3 Potential free status signals from power panel and/or refrigerating plant to the GSC ..............................15
  7.2. Outputs...............................................................................................................................................................................................16
     7.2.1 Potential free status signals from the GSC to the remote master controller...................................................16

  8. Program Example for a Profibus-DP Master with a Chiller ...................................................................................................17
  8.1 Hardware configuration for a Siemens Simatic® S7-300 CPU 315-2 DP .........................................................................17
  8.2 Programming of the first universal module with both in- and outputs ..........................................................................18
  8.3 Description of the software blocks needed for the communication..............................................................................18
  8.4 Structure of the receive data block DB17................................................................................................................................20
  8.5 Structure of the sending data block DB18...............................................................................................................................21




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                                                                                            MPI AND PROFIBUS
                           Grasso                                                           DESIGN GUIDELINES
Refrigeration Division




1.   SYSTEM ARRANGEMENT

•    The planned system provides for an arrangement comprising several piston compressor packages.
•    Each piston compressor package is controlled by a local Grasso System Control. Sequencing control for each
     piston compressor package can be performed by a contention master control (for example S7).
•    The central commands can be sent by the master control to the local package control devices using potential-
     free contacts or network signals!

2. SIGNAL COUPLING MPI
The data exchange between the local individual control systems and the primary control system is performed ac-
cording to the MPI procedure. This type of coupling is available in the “SIMATIC S7 World” only. For further infor-
mation, please refer to the system manual „Communication with SIMATIC“ Manual EWA 4 NEB 710 6075-01 02.
                    • For the MPI coupling, the data structures of the coupling signals and the protocol structure to be
                      used between the bus stations are predetermined according to the following representations.

Protocol structure

                    • Data transmission is to be done by means of a projected MPI-connection.
                    • The BUS parameters are binding for all MPI-network users!
                    • Changing the BUS-parameters is not possible!
                    • The baud-rate depends on the slowest MPI-network user. In this case the OP-terminal with
                      187,5 kBit/s is the specifying element.

MPI – BUS addresses
•    Within a MPI network a maximum of 5 GSCs are permitted.

•    The following addresses apply, if not agreed otherwise:

                                                                            MPI addresses
                                                                     CPU                      OP

                    Master Control Station                            10                      9

                                     1.   Unit Control                11                      1
                                     2.   Unit Control                12                      2
                                     3.   Unit Control                13                      3
                                     4.   Unit Control                14                      4
                                     5.   Unit Control                15                      5




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                                                                                         MPI AND PROFIBUS-DP
                           Grasso                                                          DESIGN GUIDELINES
Refrigeration Division




3.    SIGNAL COUPLING PROFIBUS DP

•     The Profibus DP –Master – Slave - procedure, accomplishes the data communication between the local pack-
      age control devices and the master control, with the GSC control devices acting as the slave‘s.
•     For the Profibus DP-coupling, the following tables show the prescribed data structures of the coupling signals
      as well as the protocol structure to be used between the packages connected to the BUS.
•     The Grasso-slave provides for 62 words respectively 124 bytes and can receive 3 words respectively 6 Bytes
      from the Master control.

Protocol Structure
                    • Data transmission is done by means of a projected Profibus DP-Master-Slave- connection, with the
                      GSC control acting as the slave.
                    • The customer is free to select the slave’s Profibus-DP address. This address must be set on the
                      DP/DP coupler.
                    • The bus settings for the communication between master and slave are also free to select.
                    • The maximum communication speed of the DP/DP coupler is 12 Mbit/s


4.    DATA WORD STRUCTURE

    Bit No                      15    14    13   12    11    10    9    8     7     6    5     4     3    2     1        0

    Low Byte „n“                 .7   .6    .5    .4   .3    .2    .1   .0

    High Byte „n + 1“                                                         .7   .6    .5    .4   .3    .2    .1      .0




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                                                                                             MPI AND PROFIBUS
                             Grasso                                                          DESIGN GUIDELINES
Refrigeration Division




5.   SIGNAL COUPLING INFORMATION

5.1 Received data

 Received word           DB18DBW              Signal description       Value range of the received data
 (Profibus- DP)          (MPI- Bus)
          1.                    0        Control word                16 Single-bits (see 5.1.1)
          2.                    2        Ext. set point              Value * 10-1 °C
          3.                    4        Ext. process value          Value * 10-1 °C

5.1.1 Control word in detail

           Bit                Signal description                     Remark
            0                 Life bit                               1 to 1 copy of life bit sent by the slave
            1                 Remote ON                              Remote master or BMS
            2                 Remote LESS capacity                   Remote master or BMS
            3                 Remote MORE capacity                   Remote master or BMS
            4                 Remote reset                           Remote master or BMS
                                         nd
            5                 Remote 2        set point              Remote master or BMS
            6                 Remote start release of compressor 1   Compressor 1 (remote master or BMS)
            7                 Motor feedback of compressor motor     Compressor 1
                         1

            8                 Reserved                               -- --
            9                 Reserved                               -- --
           10                 Reserved                               -- --
           11                 Reserved                               -- --
           12                 Reserved                               -- --
           13                 Reserved                               -- --
           14                 Reserved                               -- --
           15                 Reserved                               -- --




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                                                                                      MPI AND PROFIBUS-DP
                           Grasso                                                       DESIGN GUIDELINES
Refrigeration Division




5.2 Transmitted Data
5.2.1 Compressor 1

  Transmitted
                         DB17.DBW     Signal description
     word                                                                       Value range of the transmitted data
                         (MPI- Bus)
 (Profibus- DP)
        1.                   0        System word                               16 Single-bits, of which Bit [n+1].0 is
                                                                                the “life bit”
        2.                   2        1st Fault data word (compressor)          16 Single-bits (see chapter 6.1.1)
        3.                   4        2nd Fault data word (compressor)          16 Single-bits (see chapter 6.1.2)
                                          rd
        4.                   6        3 Fault data word (compressor)            16 Single-bits (see chapter 6.1.3)
                                          th
        5.                   8        4 Fault data word (unit)                  16 Single-bits (see chapter 6.1.4)
                                          th
        6.                  10        5 Fault data word (unit)                  16 Single-bits (see chapter 6.1.5)
                                          st
        7.                  12        1 Warning data word (compressor)          16 Single-bits (see chapter 6.1.6)
                                          nd
        8.                  14        2        Warning data word (compressor)   16 Single-bits (see chapter 6.1.7)
                                          rd
        9.                  16        3 Warning data word (unit)                16 Single-bits (see chapter 6.1.8)
        10.                 18        1st Status word (compressor)              16 Single-bits (see chapter 6.1.9)
        11.                 20        2nd Status word (compressor)              16 Single-bits (see chapter 6.1.10)
                                          rd
        12.                 22        3 Status word (unit)                      16 Single-bits (see chapter 6.1.11)
        13.                 24        Input word IW 0                           16 Single-bits (see chapter 7.1)
        14.                 26        Output word QW 0                          16 Single-bits (see chapter 7.2)
        15.                 28        Suction pressure                          Value * 10-2 bar [abs]
        16.                 30        Discharge pressure                        Value * 10-1 bar [abs]
        17.                 32        Oil pressure                              Value * 10-1 bar [abs]
        18.                 34        Crankcase pressure                        Value * 10-1 bar [abs]
        19.                 36        Suction temperature                       Value * 10-1 °C
        20.                 38        Discharge temperature                     Value * 1 °C
        21.                 40        Oil temperature                           Value * 1 °C
        22.                 42        Capacity                                  (0...100) %
        23.                 44        Motor current                             Value * 1 A
        24.                 46        Remaining period: start to start          (0...xxx) sec
        25.                 48        Remaining period: stop to start           (0...xxx) sec
        26.                 50        Remaining period: auto start delay time   (0...xxx) sec
        27.                 52        Intermediate temperature LP               Value * 1 °C
        28.                 54        Intermediate pressure                     Value * 10-1 bar [abs]
        29.                 56        Intermediate temperature HP               Value * 1 °C
        30.                 58        Motor speed                               Value * 1 rpm
        31.                 60        Process value of the GSC                  Value * 10-1 °C
        32.                 62        Set point value of the GSC                Value * 10-1 °C




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                                                                                      MPI AND PROFIBUS
                         Grasso                                                       DESIGN GUIDELINES
Refrigeration Division




6.   ALARM, WARNING AND STATUS MESSAGES
6.2 Compressor 1
In this chapter the single bits regarding the alarm, warning and status of compressor 1 are described.

6.1.1 Fault data word 1

        Bit              Fault message           Compressor 1
         0               Fault 1                 Wire failure crankcase pressure
         1               Fault 2                 Oil differential pressure too low
         2               Fault 3                 Differential (Psuc and Pdis) pressure too high
         3               Fault 4                 Pressure ratio (Psuc and Pdis) too high
         4               Fault 5                 Suction temperature too low
         5               Fault 6                 Wire failure suction temperature
         6               Fault 7                 Suction gas overheat too low
         7               Fault 8                 Discharge temperature too high
         8               Fault 9                 Suction pressure too low
         9               Fault 10                Suction pressure too high
        10               Fault 11                Wire failure suction pressure
        11               Fault 12                Discharge pressure too high
        12               Fault 13                Wire failure discharge pressure
        13               Fault 14                Intermediate pressure too high
        14               Fault 15                Wire failure intermediate pressure
        15               Fault 16                Wire failure oil pressure

6.1.2 Fault data word 2

        Bit              Fault message           Compressor 1
         0               Fault 17                Motor current too high
         1               Fault 18                Wire failure motor current
         2               Fault 19                Motor speed too low
         3               Fault 20                Motor speed too high
         4               Fault 21                Wire failure motor speed
         5               Fault 22                Emergency stop or HP-switch active
         6               Fault 23                Motor feedback too late
         7               Fault 24                Motor protection device active
         8               Fault 25                Wire failure discharge temperature
         9               Fault 26                Intermediate temperature LP too high
        10               Fault 27                Wire failure intermediate temperature LP
        11               Fault 28                Wire failure intermediate temperature HP
        12               Fault 29                Intermediate gas overheat too low
        13               Fault 30                Oil temperature too low
        14               Fault 31                Oil temperature too high
        15               Fault 32                Wire failure oil temperature

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                         Grasso                                               DESIGN GUIDELINES
Refrigeration Division




6.1.3 Fault data word 3

        Bit              Fault message   Compressor 1

         0               Fault 33         Selected refrigerant not valid with selected compressor
         1               Fault 34         Compressor data not found. Please select other compr.
         2               Fault 35         Compressor configuration not valid
         3               Fault 36         (spare)
         4               Fault 37         (spare)
         5               Fault 38         (spare)
         6               Fault 39         (spare)
         7               Fault 40         (spare)
         8               Fault 41         (spare)
         9               Fault 42         Cylinder head temperature too high
        10               Fault 43         Motor feedback missing during operation
        11               Fault 44         Liquid in compressor. Discharge temp (LP) too low
        12               Fault 45         Compressor heating. Discharge temp (LP) too high
        13               Fault 46         Liquid in compressor. Discharge temp (HP) too low
        14               Fault 47         Compressor heating. Discharge temp (HP) too high
        15               Fault 48         Pump down time elapsed. Stop pressure not reached

6.1.4 Fault data word 4

        Bit              Fault message   Unit

         0               Fault 1          (spare)
         1               Fault 2          (spare)
         2               Fault 3          (spare)
         3               Fault 4          Evaporator refrigerant level too high
         4               Fault 5          Refrigerant leak detected
         5               Fault 6          (spare)
         6               Fault 7          (spare)
         7               Fault 8          (spare)
         8               Fault 9          Wire failure oil separator temperature
         9               Fault 10         Wire failure external temperature
        10               Fault 11         Wire failure external set point
        11               Fault 12         (spare)
        12               Fault 13         (spare)
        13               Fault 14         (spare)
        14               Fault 15         (spare)
        15               Fault 16         (spare)




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                                                                                MPI AND PROFIBUS
                         Grasso                                                 DESIGN GUIDELINES
Refrigeration Division




6.1.5 Fault data word 5

        Bit              Fault message     Unit

         0               Fault 17           (spare)
         1               Fault 18           (spare)
         2               Fault 19           (spare)
         3               Fault 20           (spare)
         4               Fault 21           (spare)
         5               Fault 22           (spare)
         6               Fault 23           (spare)
         7               Fault 24           (spare)
         8               Fault 25           External temperature too low
         9               Fault 26           (spare)
        10               Fault 27           (spare)
        11               Fault 28           (spare)
        12               Fault 29           (spare)
        13               Fault 30           MPI / Profibus-DP network comm. failure
        14               Fault 31           PLC power supply interrupted
        15               Fault 32           Refrigerant data not found. Please select other refr.

6.1.6 Warning data word 1
        Bit              Warning message   Compressor 1
         0               Warning 1         Low suction gas overheat
         1               Warning 2         High discharge temperature
         2               Warning 3         High intermediate temperature (LP)
         3               Warning 4         Low intermediate gas overheat
         4               Warning 5         Low oil temperature
         5               Warning 6         High oil temperature
         6               Warning 7         High motor current
         7               Warning 8         Low motor speed

         8               Warning 9         Low suction pressure
         9               Warning 10        High suction pressure
        10               Warning 11        High discharge pressure
        11               Warning 12        High intermediate pressure
        12               Warning 13        Low oil differential pressure
        13               Warning 14        (spare)
        14               Warning 15        (spare)
        15               Warning 16        Low suction temperature



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                          Grasso                                                   DESIGN GUIDELINES
Refrigeration Division




6.1.7 Warning data word 2

        Bit              Warning message   Compressor 1
         0                Warning 17       (spare)
         1                Warning 18       (spare)
         2                Warning 19       (spare)
         3                Warning 20       (spare)
         4                Warning 21       (spare)
         5                Warning 22       (spare)
         6                Warning 23       (spare)
         7                Warning 24       (spare)

         8                Warning 25       High motor speed
         9                Warning 26       Wire failure motor current
        10                Warning 27       (spare)
        11                Warning 28       Liquid in compressor Discharge temp (LP) too low
        12                Warning 29       Compressor heating Discharge temp (LP) too high
        13                Warning 30       Liquid in compressor Discharge temp (HP) too low
        14                Warning 31       Compressor heating Discharge temp (HP) too high
        15                Warning 32       (spare)

6.1.8 Warning data word 3

        Bit              Warning message   Unit
         0               Warning 33        (spare)
         1               Warning 34        (spare)
         2               Warning 35        (spare)
         3               Warning 36        (spare)
         4               Warning 37        Low external temperature
         5               Warning 38        (spare)
         6               Warning 39        (spare)
         7               Warning 40        (spare)
         8               Warning 41        PLC power supply interrupted
         9               Warning 42        Replace PLC battery
        10               Warning 43        PLC operation mode changed
        11               Warning 44        Selection not permitted. Please check input data.
        12               Warning 45        MPI / Profibus-DP network comm. failure
        13               Warning 46        (spare)
        14               Warning 47        (spare)
        15               Warning 48        (spare)




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                                                                  MPI AND PROFIBUS
                              Grasso                              DESIGN GUIDELINES
Refrigeration Division




6.1.9 Status word 1 (compressor)

        Bit                Status message (signal – 1)
         0                 Starting 01
         1                 Running 01
         2                 Limit suct press 01
         3                 Limit disch press 01
         4                 Limit disch temp 01
         5                 Limit mot current 01
         6                 Running pull down 01
         7                 Limit timer 01

         8                 (spare)
         9                 Compressor off 01
        10                 (spare)
        11                 (spare)
        12                 (spare)
        13                 Initialisation
        14               Standby 01
        15               Motor feedback 01

6.1.10 Status word 2 (compressor)

        Bit                Status message (signal – 1)
        16                 Stopping 01
        17                 Booster wait 01
        18                 Pump down 01
        19                 (spare)
        20                 (spare)
        21                 (spare)
        22                 (spare)
        23                 (spare)
        24                 Starting pull down 01
        25                 External start 01
        26                 Start to start 01
        27                 Stop to start 01
        28                 Low oil temp 01 (start disabled)
        29                 Low suct press 01 (start disabled)
        30                 High disch press 01 (start disabled)
        31                 Failure 01



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                                                       MPI AND PROFIBUS-DP
                            Grasso                       DESIGN GUIDELINES
Refrigeration Division




6.1.11 Status word (unit)

        Bit              Status message (signal – 1)
        32               (spare)
        33               (spare)
        34               (spare)
        35               (spare)
        36               (spare)
        37               (spare)
        38               (spare)
        39               (spare)
        40               Limit ext temp
        41               (spare)
        42               Main failure
        43               (spare)
        44               (spare)
        45               (spare)
        46               (spare)
        47               (spare)




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                                                                                               MPI AND PROFIBUS
                            Grasso                                                             DESIGN GUIDELINES
Refrigeration Division




7.   DESCRIPTION OF THE IN- AND OUTPUTS

7.1. Inputs

7.1.1 Potential free actuating commands from a master controller to the GSC

     Operand             Signal description       Explanation
        E 0.3            CTRL - Package ON    •    1 - signal results in package being switched on
                                              •    0 - signal results in package being switched off
                                              •    for operating modes with “REMOTE” only
        E 0.4            CTRL –               •    1 - signal results in a compressor capacity reduction
                         Decrease capacity
                                              •    for operating modes with “REMOTE” and “external +/-” only
        E 0.5            CTRL –               •    1 - signal results in a compressor capacity increasing
                         Increase capacity
                                              •    for operating modes with “REMOTE” and “external +/-” only
        E 0.6            CTRL –               •    1 - signal results in a package starting release.
                         Starting release          This signal has no influence after the screw compressor has started.
        E 0.7            CTRL – Fault reset   •    1 - signal results in the acknowledgement of a fault.

7.1.3 Potential free status signals from power panel and/or refrigerating plant to the GSC

     Operand             Signal description       Explanation
E 0.0                    Check-back signal 1 •     1 – signal for finished star-delta motor starting and delta contactor
                         Motor in delta con-       energised
                         nection
E 0.1                    Motor protection 1 •      1 – signal: bi-metal and thermistor monitoring relay of the compressor
                         compressor drive          drive motor circuit did not trip
                         motor
E 1.1                    Liquid separator     •    1 – signal: the liquid separator level is normal
                         level
E 1.2                    Gas sensor           •    1 – signal: the gas concentration value (e.g. for ammonia) is normal
Terminals                CTRL –               •    1 – signal: the central emergency stop is ok
                         Emergency stop




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                             Grasso                                                            DESIGN GUIDELINES
Refrigeration Division




7.2. Outputs

7.2.1 Potential free status signals from the GSC to the remote master controller

    Operand              Signal designation       Explanation
       A 1.2             Signal: Package        • 1 – signal: Package is in stand-by state for central control mode (central
                         ready for operation      control mode selected; no faults and all time delays satisfied)
                         in central mode
       A 1.3             Signal: 1st Compres-   • 1 – signal: 1st Compressor drive motor is in operational state
                         sor drive motor in       (compressor delta-energised, capacity control is released)
                         operation
       A 1.4             Main fault ok          • 1 – signal: a centralised fault does not exist. The package is safe to run
                                                • 0 – signal: a centralised fault exists. The package is not safe to run
       A 1.5             Auxiliary output       • 1 – signal: the selected functionality is active or the limit value has been
                                                  reached. Selectable functionality for this output: “Standby”, “Starting”,
                                                  “Limited”, “Min capacity reached”, “Max capacity reached”, “Neutral”,
                                                  “Warning”, “More capacity”




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                                                                        MPI AND PROFIBUS
                         Grasso                                         DESIGN GUIDELINES
Refrigeration Division




8.   PROGRAM EXAMPLE FOR A PROFIBUS-DP MASTER WITH A CHILLER

8.1 Hardware configuration for a Siemens Simatic® S7-300 CPU 315-2 DP




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                                                                                      MPI AND PROFIBUS-DP
                         Grasso                                                         DESIGN GUIDELINES
Refrigeration Division




8.2 Programming of the first universal module with both in- and outputs




F    Attention!
     The consistency is related to the total length of the data bytes. When reading or writing the bytes this
     must be done using the same length as defined in the hardware configuration. An example of how to read
     and write the bytes using the DP/DP coupler is given by function FC1. In this example the read data is
     written in DB17 and the write data (sent to the DP/DP coupler) is read out of DB18.


8.3 Description of the software blocks needed for the communication
To detect communication failures between master and slave a life bit is sent by the GSC (slave) to the master. The
life bit consists of a pulsating bit with a slow frequency. The master returns this bit 1 to 1 to the slave. As soon as
this bit is not returned to the slave within a defined time, e.g. cable disconnected or master in stop, a communica-
tion failure is activated on the slave. By monitoring the pulsation of the life bit, the master can also use this bit to
detect communication failures.
In Network 4 of FC1 (see next page) the way in which the master returns the life bit to the slave is shown.
Notice that the address (LADDR) must be entered in hexadecimal format. The maximum length that can be han-
dled by SFC14 (receive) and SFC15 (send) is 32 bytes.




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                                  MPI AND PROFIBUS
                         Grasso   DESIGN GUIDELINES
Refrigeration Division




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                         Grasso                  DESIGN GUIDELINES
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8.4 Structure of the receive data block DB17




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8.5 Structure of the sending data block DB18




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