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For **Bulk Milk Chiller (BMC) with Thermal Battery IoT integration**, there is **no universal Modbus register map** because each OEM controller uses its own map. However, for a **custom IoT gateway or controller**, a standard **industrial Modbus register structure** can be designed so SCADA, dairy ERP, or cloud systems can easily integrate.
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Below is a **practical Modbus RTU/TCP register map typically used for Milk Chiller monitoring systems**.
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---
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# 1. Modbus Communication Parameters
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Typical configuration used in dairy equipment:
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| Parameter | Value |
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| --------- | ------------ |
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| Protocol | Modbus RTU |
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| Interface | RS485 |
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| Baud rate | 9600 / 19200 |
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| Data bits | 8 |
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| Parity | Even |
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| Stop bits | 1 |
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| Slave ID | 1–247 |
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IoT gateway can convert **RS485 → MQTT / HTTP / Cloud**.
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---
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# 2. Input Registers (Sensor Data)
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**Function Code: 04**
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| Register | Parameter | Unit | Description |
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| -------- | ------------------------- | ------ | --------------------- |
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| 30001 | Milk Temperature | 0.1 °C | Milk tank temp |
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| 30002 | Thermal Battery Temp | 0.1 °C | PCM temperature |
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| 30003 | Evaporator Temp | 0.1 °C | Cooling coil |
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| 30004 | Compressor Discharge Temp | 0.1 °C | Compressor protection |
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| 30005 | Ambient Temperature | 0.1 °C | Outside environment |
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| 30006 | Milk Tank Level | Liters | From level sensor |
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| 30007 | Milk Flow Rate | L/min | Milk intake |
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| 30008 | Compressor Current | 0.1 A | Motor load |
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| 30009 | Voltage | 0.1 V | Supply voltage |
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| 30010 | Power Consumption | W | Real-time power |
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# 3. Holding Registers (Configuration)
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**Function Code: 03**
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| Register | Parameter | Unit |
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| -------- | --------------------------- | ------ |
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| 40001 | Milk Cooling Setpoint | °C |
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| 40002 | Compressor Start Temp | °C |
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| 40003 | Compressor Stop Temp | °C |
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| 40004 | Thermal Battery Charge Temp | °C |
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| 40005 | Alarm Temp High | °C |
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| 40006 | Alarm Temp Low | °C |
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| 40007 | Compressor Restart Delay | sec |
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| 40008 | Milk Tank Capacity | Liters |
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# 4. Coil Registers (Digital Outputs)
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**Function Code: 01**
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| Register | Control |
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| -------- | --------------------------- |
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| 00001 | Compressor ON/OFF |
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| 00002 | Agitator Motor |
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| 00003 | Milk Pump |
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| 00004 | Thermal Battery Charge Mode |
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| 00005 | Alarm Buzzer |
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| 00006 | Remote Reset |
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# 5. Discrete Inputs (Status)
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**Function Code: 02**
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| Register | Status |
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| -------- | ----------------------- |
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| 10001 | Compressor Running |
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| 10002 | Agitator Running |
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| 10003 | Power Available |
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| 10004 | Door Open |
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| 10005 | High Temperature Alarm |
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| 10006 | Low Temperature Alarm |
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| 10007 | Thermal Battery Charged |
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| 10008 | Sensor Fault |
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# 6. Data Logging Registers
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For **IoT analytics**
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| Register | Parameter |
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| -------- | -------------------------- |
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| 31001 | Total Compressor Run Hours |
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| 31002 | Total Energy Consumption |
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| 31003 | Milk Collected Today |
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| 31004 | Cooling Cycles Today |
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| 31005 | Last Alarm Code |
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# 7. Alarm Codes
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| Code | Alarm |
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| ---- | --------------------------- |
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| 1 | Milk temperature high |
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| 2 | Compressor overload |
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| 3 | Low refrigerant pressure |
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| 4 | Thermal battery not charged |
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| 5 | Sensor failure |
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| 6 | Power failure |
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# 8. Example Modbus Read
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Example: Read milk temperature
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```
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Slave ID : 01
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Function : 04
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Register : 30001
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Length : 01
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```
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Response:
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```
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01 04 02 00 FA CRC
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```
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`00FA = 250 → 25.0 °C`
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---
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# 9. Typical IoT Gateway Architecture
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```
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BMC Controller
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│
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│ RS485 Modbus
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▼
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IoT Gateway
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(ESP32 / STM32 / Linux)
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│
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4G / NB-IoT
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│
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MQTT
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│
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Cloud Dashboard
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```
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---
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# 10. Recommended Sensors for BMC IoT
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| Parameter | Sensor |
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| ------------------ | ---------------------- |
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| Milk temperature | PT100 / DS18B20 |
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| Tank level | Ultrasonic / Load cell |
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| Flow | Milk flow meter |
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| Power | Energy meter |
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| Compressor current | Hall current sensor |
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💡 **Important practical note**
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Most dairy chillers (including those from Promethean Power Systems) **do not expose native Modbus**, so an **external IoT controller** usually reads sensors directly or taps into PLC signals.
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---
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If you want, I can also provide:
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1️⃣ **Complete SAME54 firmware architecture for BMC IoT controller**
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2️⃣ **RS485 Modbus gateway firmware with MQTT cloud upload**
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3️⃣ **Full hardware BOM (~₹4500 IoT board) for 1000 milk collection centers**.
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