CDL Gateway™ Version 1.05 Installation and Operation Guide MONICO, INC. 3403 Chapel Square Spring, Texas 77388 Tel: (281) 350-8751 sales@MONICOINC.com www.MONICOINC.
v1.05 6.26.09 Table of Contents Introduction ............................................................................................................................................................ 3 Section 1: Power Supply ........................................................................................................................................ 4 Section 2: Hardware Installation .............................................................................................................
v1.05 6.26.09 Introduction The CDL Gateway™ is a completely new generation of communications interface from Monico. It does not require any intermediary devices to communicate with all engines that utilize the Data Link for primary communications. This includes the vast majority of industrial engines, marine engines, large construction and mining equipment engines, and generator sets that use the ADEM II & ADEM III ECM’s, EIS, and AFR controls.
v1.05 6.26.09 Figure 1.0 Gateway Connections Overview Section 1: Power Supply The CDL Gateway™ requires regulated 24 Vdc +/- 10% with 1000 ma power maximum. Must use Class 2 or SELV rated power supply. You may use either an Isolated power supply, or the properly grounded engine batteries to power the Gateway. If using an isolated power supply, make sure to use CDL Monitor 2.0. If power is applied, the green STS light will function.
v1.05 6.26.09 CAUTION Reversing wire polarity may cause damage to your Gateway. This damage is not covered by warranty. If in doubt about which wire is which on your power supply, check with a meter. If you must use an external power supply, it is very important that the power supply is mounted correctly if the unit is to operate reliably. Please take care to observe the following points: – The power supply must be mounted close to the unit, with usually not more than 6 feet (1.
v1.05 6.26.09 EMC INSTALLATION GUIDELINES Although the CDL Gateway™ is designed with a high degree of immunity to Electromagnetic Interference (EMI), proper installation and wiring methods must be followed to ensure compatibility in each application. The type of electrical noise, source or coupling method into a unit may be different for various installations. Cable length, routing, and shield termination are very important and can mean the difference between a successful or troublesome installation.
v1.05 6.26.09 CF – CompactFlash LED indicates card status and read/write activity 4. MEMORY: On-board User Memory: 4 Mbytes of non-volatile Flash memory. On-board SDRAM: DSPSX: 2 Mbytes DSPGT: 8 Mbytes Memory Card: CompactFlash Type II slot for Type I and Type II cards. 5. REAL-TIME CLOCK: Typical accuracy is less than one minute per month drift. Crimson 2.0’s SNTP facility allows synchronization with external servers. Battery: Lithium Coin Cell. Typical lifetime of 10 years at 25 ºC.
v1.05 6.26.09 Section 2: Hardware Installation DIN rail should be mounted horizontally so that the unit’s ventilation holes are vertical in relation to cabinet orientation. A minimum clearance of 1 inch (25.4 mm) should be maintained above and below the unit in order to ensure proper thermal regulation. Figure 2.1 Hardware Installation Figure 2.
v1.05 6.26.09 Section 3: CDL Connection to the Engine Connection to the Data Link is via the RJ-45 Jack (Figure 3.1). The CDL is a differential buss that is relatively noise immune, but care must be taken not to create ground loops and good wiring practices are critical. This RJ-45 port has built-in receive (Rx-red) and transmit (Tx-Green) LED lights which will show transmit and receive activity. If there is no action with these lights after 5-10 seconds, then the Data Link is not active or not present.
v1.05 6.26.09 Host Connection-RS-232 via RJ-11 Jack Figure 4.2 RS-232 Connections Host Connections-RS-485/RS-422 via RJ-45 Jack Figure 4.
v1.05 6.26.09 Figure 4.3 RS-485/RS-422 Schematic Please note that different companies use different terminology. For example, some use TxA and TxB to describe 2- wire RS-485 connections. Some use Tx+ and Tx-. In general. TxA=Tx- and TxB=Tx+ For 2-wire RS-485, use Pin#7 = (+) and Pin#8 = (-). Host Connections-TCP/IP over Ethernet via RJ-45 Shielded Jack Ethernet Figure 4.4 Ethernet Connections ETHERNET COMMUNICATIONS Ethernet communications can be established at either 10 BASE-T or 100 BASE-TX.
v1.05 6.26.09 Section 5: Troubleshooting LED’s STS – STATUS LED The green Status LED provides information regarding the state of the Gateway. This includes indication of the various stages of the start-up routine (power-up), and any errors that may occur. Startup Routine LED Rapidly Flashing Steady Indication Gateway is currently loading program Gateway is operating normally Table 5.1 STS LED SERIAL HOST PORTS - TX/RX LED’S LED Green Red Indication Transmitting Receiving Table 5.
v1.05 6.26.09 Section 6: MonicoView Programmer The MonicoView Programmer is a critical part of the product. This free software is used to develop programs or modify files supplied from the factory to meet your needs. Please check on our website for the latest version at www.monicoinc.com.
v1.05 6.26.09 Subsequent Installations When asked to go to Windows Update to find a driver, select “No, not at this time” and click “Next”. This will bring up the screen shown in Figure 6.1 below and the “Install Automatically” should be selected by default. If your first installation is not successful, you will need to follow the instructions at the end of this section to navigate to Device Manager and perform a manual install. Figure 6.
v1.05 6.26.09 Click “Finish” when this screen is done. There is another driver that will need to be loaded, but it will not be found until you download the program to the CDL Gateway™. After the initial installation or update of the CDL Gateway™ program, Microsoft will find new hardware again and you will go through the same process again, but instead of calling it “G3 Loader”, it will be called “G3 HMI”.
v1.05 6.26.09 Interface. When you delete the parameter, you are only removing it from the CDL communications. Adjusting Port Settings The CDL Gateway™ has several HOST PORTS including two RS-232 ports, an RS-485 port, and an Ethernet port. MonicoView can be used to adjust the settings for any of these ports and to disable the ports that are not being used. For example, if you need to change the port settings for the RS-232 port you would see: Figure 6.
v1.05 6.26.09 The only difference with the RS-485 port is choosing whether you want 2-wire RS-485 or 4wire RS-485 or RS-422. This screen is shown in Figure 6.4 below. Figure 6.4: RS-485 Serial Port Settings Settings for the Ethernet port are show in Figure 6.5 and include setting the Port Mode where you set whether to Manually Configure the IP address, request an IP address from a DHCP server or use IEEE 802.3. Then enter the IP address if manually configured and the associated Network Mask and Gateway.
v1.05 6.26.09 Figure 6.5: TCP/IP Ethernet Port Settings Disabling and Enabling Ports The CDL Gateway™ is a standard product that ships pre-configured with all ports active and populated with a full array of values. Since each port will have over 400 registers to update, it is recommended that you disable the unused ports by selecting the port and unchecking the box under Device Settings labeled ENABLE DEVICE as shown in Figure 6.6 below.
v1.05 6.26.09 Figure 6.6: Enable/Disable Ports Viewing Live Data MonicoView can also be used to view live data for each data block. Highlight an individual data block and click the button labeled View Block. This will cause the software to connect to the CDL Gateway™ and display the current data for each parameter. Figure 6.
v1.05 6.26.09 A table will appear that will show the data block, the parameter tag, and the value in that register in both Decimal and Hexadecimal. Figure 6.8: Live Block Viewer Parameter Status Block A special device named “PIDStatusValues” is usually installed under the Programming RS232 port. Blocks 1-4 contains registers showing internal details for each possible parameter. These parameters are best viewed in Hex format. The left-hand character (XXxx) indicates the current action in the driver.
v1.05 6.26.09 Figure 6.9: Parameter Status Block Raw Data Block The second Device installed under the RS-232 Programming Device is called “PIDRawValues”. Blocks 1-4 under this Device are setup to view raw values for troubleshooting purposes. These values are the raw values read directly from the CDL Link before any gain is applied or unit conversions are performed. Note that in most of the Modbus Versions, this block is omitted because all values are raw.
v1.05 6.26.09 will automatically start MonicoView. Select “Link” and then “Send”. This will begin the download process. During this installation, you will be asked to go through another USB Driver installation as shown above. Then MonicoView will automatically finish loading the upgraded program. REMEMBER, IF THIS IS THE FIRST USB DRIVER INSTALLATION ON A PARTICULAR COMPUTER, YOU MUST USE THE MANUAL INSTALLATION METHOD OUTLINED ABOVE. CDL MONITOR 2.
v1.05 6.26.09 Figure 7.
v1.05 6.26.09 If Bit 0 of this value is high, then the code is currently ACTIVE. If low, then it is inactive. Figure 7.2 FaultCode Data Block Figure 7.3 below shows a data block example with the Details Fault information where: FaultCount=Number of Occurrences of this specific Code FaultFirst=First Occurrence in Engine Operating Hours FaultLast=Last Occurrence in Engine Operating Hours The example in Figure 7.
v1.05 6.26.09 Figure 7.3 Details Fault Code Block Example Creating Fault Blocks The pre-configured factory programs do not usually contain fault blocks because it takes up resources and is not required in the majority of applications.
v1.05 6.26.09 1. After highlighting the desired device, click on Add Gateway Block. Then highlight the Gateway Block and Click EDIT under the Starting Address section. Choose the appropriate starting address. 2. Then click EDIT under Block Size to choose the total number of registers you want to use for fault codes. So, for five codes using all details you will need 35 registers. 3. Highlight the first register and double-click on FaultSource on the right-hand side of the screen.
v1.05 6.26.09 Figure 7.
v1.05 6.26.09 Appendix A: CDL Gateway™-Modbus Version Modbus Version Overview The Standard Modbus Version offers three host ports in slave mode. They are: • Modbus RTU Slave over RS-232 via the RJ-11 jack • Modbus RTU Slave over RS-485 (2-wire or 4-wire) via RJ-45 jack • Modbus TCP/IP Slave over Ethernet via RJ-45 jack Other Modbus versions are available upon request such as a Modbus Master version.
v1.05 6.26.09 Modbus Register Conversion Details All data is transmitted from the engine network in Metric Units. Therefore, some of the raw values from the modbus registers will require calculations to convert them into actual engine data. Any unit conversion will need to take place after the following instructions. The following information provides a list of the conversion types and the calculations necessary to provide actual engine measurement values.
v1.05 6.26.09 59 Generator Phase A Power Factor Lead/Lag Status 30059 0=Current lags voltage, 1=Current leads voltage, 224-255 Fault Identifiers* 0=Current lags voltage, 1=Current leads voltage, 224-255 Fault Identifiers* 0=Current lags voltage, 1=Current leads voltage, 224-255 Fault Identifiers* 0=Current lags voltage, 1=Current leads voltage, 224-255 Fault Identifiers* 0=Breaker open, 1=Breaker closed, 228=Breaker sensor input shorted low 0=coolant pressure OK, 1=coolant pressure too high, 2=Too Low.
v1.05 6.26.09 Multiple Status Bits Read from modbus register as unsigned integer. The value is composed of more than one status condition. This is accomplished by setting the appropriate bits for each status condition. See details below: Monico PID Description Id Modbus Manual Remarks Address 6 Oxygen Sensor Status 30006 Bits set to 1 indicate Status: 8=start cal.
v1.05 6.26.09 Monico PID Description Id Modbus Manual Remarks Address 94 GSC Shutdown Status 30094 Organized by bit pairs where for each pair 0=Shutdown Inactive, 1=Shutdown Active, 3=Not Available: Bits 2,1=Diag Code. Bits 4,3=Coolant Loss. Bits 6,5=Emg Stop. Bits 8,7=Spare Fault. Bits 10,9=High Coolant Temp. Bits 12,11=Low Oil Psi. Bits 14,13=Overcrank. Bits 16,15=Overspeed.
v1.05 6.26.09 Monico PID Description Id Modbus Manual Remarks Address 239 Warning Status 30239 240 Shutdown Status 30240 241 Engine Derate Status 30241 Each of the first 24 bits represents warning status.
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v1.05 6.26.09 Monico PID Description Id Modbus Manual Remarks Address 260 High Exhaust Port Temp Deviating Low Warning 30260 261 High Exhaust Port Temp Deviating Low Shutdown 30261 active; 10 = Undefined; 11 = Not available, or not installed.
v1.05 6.26.09 Appendix B: CDL Gateway™-CCM Translator Modbus Version Modbus Address Description The CDL Gateway™-Modbus Version has a very simple, pre-assigned, address system that starts at 30001 and goes through 30429 for Modbus Function code “4” and 40001-40429 for Modbus Function Code “3”. Currently, it is necessary to specify whether you will be using Function Code “3” or “4”. The Modbus Data Map is available on the Downloads page of the Monico, Inc. web site (www.monicoinc.com).
v1.05 6.26.09 Diagnostic Codes Will be supported in the near future 0=False (OFF), NonZero =True (ON) w/Fault Codes A value of 0 indicates that the status is inactive, disabled or off. A value of 1 indicates that the status is active, enabled or on. 0=Stop (OFF), NonZero=Start (ON) A value of 0 indicates that the status is inactive, disabled or off. A value of 1 indicates that the status is active, enabled or on. Multistate Read from Modbus register as unsigned integer.
v1.05 6.26.09 Monico PID Description Id Modbus Manual Remarks Address 24 Generator Phase Select 30026 0=Phase A-B Volts A current, 1=Phase B-C Volts B current, 2=Phase C-A Volts C current 0=700v, 1=150v, 2=300, 3=500, 4=600, 5=750, 6=3k, 7=4.5k, 8=5.
v1.05 6.26.09 Monico PID Description Id Modbus Manual Remarks Address 60 Diagnostic Status Summary 30062 Bits 2-1: 0=None, 1=Level 1 Warning, 2=Level2 Warning, 3=Level 3 Warning. Bit 3&4 not used. Bit 5: 0=No logged events, 1=At least 1 logged event. Bit 6 not used. Bit7: 0=No logged diag., 1=At least 1 logged diag. Bit8: 0=No active diag. 1=At least 1 active diag.
v1.05 6.26.09 0=Enabled, NonZero=Disabled A value of 0 indicates that the status is inactive, disabled or off. A value of 1 indicates that the status is active, enabled or on. 0=Inactive, NonZero=Active A value of 0 indicates that the status is inactive, disabled or off. A value of 1 indicates that the status is active, enabled or on. Hex to Long Integer The value is contained in 2 consecutive Modbus registers.
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v1.05 6.26.09 Appendix C: Modbus Viewer Program A Modbus Viewer Program is offered as an option to allow easy Reading and Writing of CCM data located in the Translator Modbus addresses. A Freeware version that only reads Modbus registers is available for download from www.monicoinc.com/downloads. Appendix D: GE Fanuc Version Notes The GE Fanuc version gathers all Engine Data and creates a data map that is pushed to the PLC with the Gateway acting as the Master device.
v1.05 6.26.09 Parameter Raw Values The four blocks for viewing raw CDL Values are mapped to AI2501-AI2907. These parameters are usually only used for troubleshooting purposes. It is recommended that you disable this device after satisfactory installation is achieved. This will optimize the performance of the CDL Gateway™. You can always enable the device again to see them in the future.
v1.05 6.26.09 Figure E.1: Parameter Mapping An example of the overall mapping using the other two data types is shown in E.2 below: Figure E.
v1.05 6.26.09 SLC, MicroLogix, and PLC-5 Style Versions Since the SLC series do not support the Double Integer data type, these 32 bit integers are placed in the Floating Point registers. In most cases, the Gateway acts as a DF1 Master and pushes the engine data into the mapped data registers in the PLC, but it can read data from the PLC as well. In most cases, the Gain and Unit Conversions (For US units) are already done which saves substantial programming time in the PLC.
