GCP-MG Ethernet Modbus gateway User manual
Contents
1. Block Modbus GCP 30 GCP 30 GCP 30 manual designator Unit address MUX word no 3 1001 0 1 1 Generator voltage delta V12 V 3 1003 0 2 2 Generator frequency f Hz 3 1005 0 3 3 Actual generator real power P kW 3 1007 1 2 5 Real power set point value kW 3 1009 2 1 7 Busbar voltage delta V12 V 3 1011 2 2 8 Mains voltage delta V12 V 3 1013 3 2 11 Actual mains interchange import export real power kW 3 1015 4 3 15 Generator voltage delta V23 V 3 1017 5 1 16 Generator voltage delta V31 V 3 1019 5 2 17 Generator voltage delta V1N V 3 1021 5 3 18 Generator voltage delta V2N V 3 1023 6 1 19 Generator voltage delta V3N V 3 1025 6 3 21 Engine speed measured via the pickup rpm 3 1027 7 1 22 Generator current in L1 A 3 1029 7 2 23 Generator current in L2 A 3 1031 7 3 24 Generator current in L3 A 3 1033 8 1 25 Actual generator reactive power kW 3 1035 8 2 26 Generator cos phi 3 1037 8 3 27 Current reserve power in the system in KW kW 3 1039 9 1 28 Current actual real power in the system kW 3 1041 10 2 32 Busbar frequency Hz 3 1043 11 1 34 Mains voltage delta V23 V 3 1045 11 2 35 Mains voltage delta V31 V 3 1047 11 8 36 Mains voltage delta V1N V 3 1049 12 1 37 Mains voltage delta V2N V 3 1051 12 2 38 Mains voltage delta V3N V 3 1053 12 8 39 Mains frequency out off VN12 VN23 VN31 V 3 1055 13 1 40 Mains current in L1 A 3 1057 13 2 41 Mains reactive power kVAR 3 1059 13 8 42 Mains power factor2. 6 UMGCPMG 0801 Installation Mounting rules A The enclosure provides protection against solid objects according to IP 20 NEMA Type 1 protection rating When mounting the enclosure observe the following rules e Avoid splash water and water drops e Avoid aggressive gas steam or liquids Avoid dusty environments Make sure there is sufficient air ventilation and clearance to other devices mounted next to the module Do not exceed the specified operational temperatures Mount inside a sealed electrical switchboard or cubicle e Observe applicable local regulations like EN60204 VDE0113 Powering the GCP MG 1212 Before connecting power please follow the rules in the section called Safety precautions and the section called Before connecting anything Power is supplied via a 3 81 mm 2 pin pluggable terminal block Phoenix Contact Mini Combicon type MC1 5 2 ST 3 81 located at the top side of the mounted module refer to Figure 2 1 Location of connectors The following table and picture shows the power terminal socket pinout Pin Signal Function 1 V Positive voltage supply 10 30 V DC 2 V Negative voltage supply ground Table 3 1 Power supply connector pinout Make sure that the polarity of the supply voltage is correct before connecting any device to the serial and CAN ports A wrong polarity can cause high currents on the ground plane between the V power supply pin and the CAN
3. at a single point The shield must not be connected to the GND pin Wiring the Modbus RS 232 interface The module s primary RS 232 port is used for serial communication to a Modbus Master device The GCP MG is a Modbus slave device The Primary RS 232 Modbus port connector is a male 9 pin D sub type located at the bottom side of the mounted module refer to Figure 2 1 Location of connectors It has industry standard EIA 574 data terminal equipment DTE pinout as shown in the follow ing table and picture Table 3 4 Primary RS 232 Modbus connector pinout Pin Signal Function Direction 1 DCD unused in 2 RXD Receive data in 3 TXD Transmit data out 4 DTR unused out 5 GND Signal ground 6 DSR unused in 7 RTS unused out 8 CTS unused in 9 RI unused in FG Connector frame shell is internally connected to ground e Maximum cable length is 15 m 50 ft or a length equal to a line capacitance of 2500 pF both at the maximum standard bit rate of 20 kbps If operating at higher bit rates the maximum cable length drops to 3 m 10 ft at a bit rate of 57 6 kbps UMGCPMG 0801 GCP MG Ethernet Modbus gateway User manual The RS 232 cable must be shielded and the shield must be connected to a protective ground at a single point to assure a high degree of electromagnetic compatibility and surge protection The shield must not be connected to the GND pin or the conne
4. 24 V DC 10 30 V power supply Status LEDs for power Ethernet link device status and Modbus CAN status UMGCPMG 0801 Description Chapter 2 Description The power CAN and RS 485 RS 422 connectors are placed on the top side of the module The RS 232 and Ethernet connectors are placed on the bottom side of the module as shown in the following illustration tot 1 N TO HERES 2 TOP VIEW Oo Wiss o Figure 2 1 Location of connectors Clear front cover Primary RS 232 Modbus connector Secondary RS 232 Diagnostic connector O Ethernet connector DIN rail clip Q Power LED Ethernet link LED O Device status LED Modbus CAN status LED Power terminal block socket Modbus RS 485 terminal block socket CAN connector UMGCPMG 0801 3 This page intentionally left blank UMGCPMG 0801 Installation Chapter 3 Installation Safety precautions HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH Only qualified workers should install this equipment Such work should be per formed only after reading this entire set of instructions e NEVER work alone Before performing visual inspections tests or maintenance on this equipment dis connect all sources of electric power Assume that all circuits are live until they have been completely de energized tested and tagged Pay particular attention to the design of the
5. Click on the About menu entry on the menu bar to show the product information as shown below Detailed Status Product Information Product Name GCP MG Hardware Version X105 Firmware Version 1 0 Serial Number 00123 Figure 5 5 About page This product information is important for service and support inquiries The following product information is provided Product name The name of the product Hardware version GCP MG hardware version Firmware version The firmware version that is installed on the GCP MG Serial number The serial number of the GCP MG The serial number is specific to your device Configuring and commissioning The configuration pages are accessed by clicking on the Configuration menu entry on the menu bar which then expands a configuration sub menu All configuration settings are kept in the device non volatile memory If you make changes to any settings remember to save each page before changing to a different page Configuring Ethernet and IP Select the Configuration Ethernet amp IP sub menu from the menu bar to open the Ether net and IP settings which are shown below 22 UMGCPMG 0801 Web browser based management Configuration Ethernet MAC Address 00 50 C7 67 70 7B IP Settings IP Address mes 254 o jo j Subnet Mask 255 2s o o Gateway Address 0 0 0 0 Figure 5 6 Ethernet and IP settings page The following Ethe
6. GCP 30 1 1 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 801 GCP 30 2 2 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 802 GCP 30 3 3 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 803 GCP 30 4 4 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 804 GCP 30 5 5 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 805 GCP 30 6 6 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 806 GCP 30 7 7 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 807 GCP 30 8 8 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 808 GCP 30 9 9 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 809 GCP 30 10 10 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 810 GCP 30 11 11 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 811 GCP 30 12 12 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 812 GCP 30 13 13 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 813 GCP 30 14 14 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 814 GCP 30 15 15 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 815 GCP 30 16 16 3 0001 3 0100 4 0001 4 0003 3 1001 3 1076 816 LS 4 1 17 3 0001 3 0100 4 0003 3 1001 3 1034 817 LS 4 2 18 3 0001 3 0100 4 0003 3 1001 3 1034 818 LS 4 3 19 3 0001 3 0100 4 0003 3 1001 3 1034 819 LS 4 4 20 3 0001 3 0100 4 0003 3 1001 3 1034 820 LS 4 5 21 3 0001 3 0100 4 0003 3 1001 3 1034 821 LS 4 6 22 3 0001 3 0100 4 0003 3 1001 3 1034 822 LS 4 7 23 3 0001 3 0100 4 0003 3 1001 3 1034 823 LS 4 8 24 3 0001 3 0100 4 0003 3 1001 3 1034 824 Table 7 2 Modbus slave ID relationship A standard LS 4 occupies only the range from 3 0001 to 3 0029 The remai
7. It has industry standard EIA 574 data terminal equipment DTE pinout as shown in the following table and picture 10 UMGCPMG 0801 Installation ES z Pin Signal Function Direction 1 NC 2 RXD_ Receive data in 3 TXD Transmit data out 4 NC 5 GND Signal ground 6 NC 7 NC 8 NC 9 NC FG Connector frame shell is internally connected to ground Table 3 6 Secondary RS 232 Diagnostic connector pinout e Maximum cable length is 15 m 50 ft or a length equal to a line capacitance of 2500 pF both at the maximum standard bit rate of 20 kbps If operating at higher bit rates the maximum cable length drops to 3 m 10 ft at a bit rate of 57 6 kbps The cable must be shielded and the shield must be connected to a protective ground at a single point to assure a high degree of electromagnetic compatibility and surge protection The shield must not be connected to the GND pin or the connector shell To connect the GCP MG to a PC Personal Computer or any other device with data terminal equipment DTE pinout you need a null modem or cross over cable UMGCPMG 0801 11 This page intentionally left blank 12 UMGCPMG 0801 Ethernet amp IP configuration Chapter 4 Ethernet amp IP configuration Before configuring the GCP MG obtain a unique static IP address subnet mask and de fault gateway address from your network administrator The factory default
8. Modbus can be polled significantly faster than the update rate on the CAN bus However faster poll rates would not offer higher update cycles of the data values The GCP MG al lows a maximum of 2 connections via Modbus TCP and in addition one serial connection via either RS 485 or RS 232 Modbus Read Input Reai ua Read Input Redislers Modbus PLC GCP MG Multiplexed CAN messages q Figure 6 1 Gateway operation For remote control a Modbus master writes control words to a dedicated internal data table which is then cyclically sent to the corresponding GCP 30 or LS 4 unit One remote control data table is processed every 100 ms This makes the remote control update cycles depend on the number of units enabled for remote control For example if 3 GCP 30s are enabled for remote control it takes 300 ms to send all control words to all GCP 30s if all 16 GCP 30 and all 8 LS 4 units are enabled for remote control it takes 2 4 seconds 16 8 x 0 1 s to transmit all control words to the connected units UMGCPMG 0801 27 GCP MG Ethernet Modbus gateway User manual LED indicators Four LEDs located at the front panel indicate the status of the module The LEDs assist maintenance personnel in quickly identifying wiring or communication errors A LED test is exercised at power up cycling each LED off green and then red for approx imately 0 25 seconds At the same time the power on self test of the module is perfo
9. This opens either the GCP 30 settings or the LS 4 settings as shown below Configuration GCP 30 Modbus Access SCP 30 ANId Modbus Modbus GCP 30 CANId Modbus Modbus Slave Id Access Slave Id Access 1 801 1 monitored control v 9 809 9 read only v 2 802 2 read only v 10 810 10 read only M 3 803 3 readonly 11 811 11 read only v 4 804 4 read only v 12 812 12 read only v 5 805 5 control v 513 813 13 read ony v 6 806 6 read only v 14 814 14 read only v 7 807 7 read only 15 815 15 read only 8 808 8 read only v 16 816 16 read only v Cancel Figure 5 8 GCP 30 settings page The CAN identifiers and Modbus slave identifiers are preassigned and cannot be changed The following Modbus access options can be selected disabled Modbus access to this unit is completely disabled The gateway does not respond to a Modbus master query and ignores messages for the associated Modbus slave ID The associated slave ID can be used by another Modbus device connected to the Modbus network read only Modbus access is enabled for read only data No remote control is possible access to the remote control data table 4 0001 will result in Modbus exception code 03 Illegal Value being returned control Modbus access is enabled for reading and for remote control No supervision of Mod bus master activity takes place See Monitored Control Before being able to use Re mote Control pleas
10. cable length Ethernet frame types 1 1 for Modbus either RS 232 or RS 485 software configurable 1 for diagnostics RS 232 1 Power green Ethernet link green 2 status bi color red green Web browser based Watchdog supervision brown out detection male 9 pin D sub CiA DS 102 pin out ISO 11898 non isolated 125 kBit s 64 CAL 2 0 3 81 mm 6 pin pluggable terminal block header Mini Combicon EIA 485 A 2 wire non isolated 300 600 1200 2400 4800 9600 19200 57600 115200 bps 32 Modbus RTU slave male 9 pin D sub DTE EIA 574 pin out EIA 232 F non isolated RXD TXD RTS CTS DTR DSR DCD RI 300 600 1200 2400 4800 9600 19200 57600 115200 bps Modbus RTU slave male 9 pin D sub DTE EIA 574 pin out EIA 232 F n a RXD TXD 9600 bps ASCII terminal 8 pin RJ 45 socket for Cat 5 shielded twisted pair IEEE 802 3i 10BASE T 1 5 kV galvanic 10 Mbit s half duplex 100 m 328 ft 802 3 UMGCPMG 0801 41 GCP MG Ethernet Modbus gateway User manual Protocols Concurrent connections Enclosure Material Mounting Classification Type rating Power supply Connector Voltage Current Intrinsic consumption Environmental Operating temperature Storage temperature Humidity Operating ambience Physical Dimensions Weight Dimensions 101 0 mm 3 98 in OW Modbus TCP slave HTTP IP TCP ARP 2 Modbus TCP 2 HTTP Self extinguishing PC ABS blend UL 94
11. 2 wire v RTU 1900 v 8 v 14 even v Figure 5 9 Modbus settings page The following Modbus settings can be entered Physical layer Can be set to two wire TIA EIA 485 RS 485 or TIA EIA 232 F RS 232 mode RS 485 is the default Depending on this setting either the D sub RS 232 connector or the terminal block connector RS 485 of the GCP MG is utilized Transmission mode Only RTU mode can be selected here Baud rate 9600 and 19200 are the most common baud rates for Modbus 19200 is the default set ting Data bits Only 8 data bits can be selected here which is a requirement for RTU Stop bits Can be configured to be 1 or 2 The Modbus standard mandates that 2 stop bits are configured when using no parity UMGCPMG 0801 25 GCP MG Ethernet Modbus gateway User manual Parity Changes parity mode to either none even or odd The default parity mode for Modbus is even parity Once you click Save the new settings are stored and applied instantly A confirmation mes sage is shown Remote restarting the device You can perform a remote restart of the device from the web interface A remote restart is similar to power cycling the device Possibly connected clients are disconnected and communication is interrupted until the device has rebooted To perform a remote restart click on the Configuration sub menu and then click on the Restart menu entry This will open the device restart page as shown below Configu
12. 6 Voltage L2N system A V 3 1011 2 1 7 Voltage L3N system A V 3 1013 2 2 8 Frequency system A Hz 3 1015 2 3 9 Current L1 system A A 3 1017 3 1 10 Current L2 system A A 3 1019 3 2 11 Current L3 system A A 3 1021 3 3 12 Power factor 3 1023 4 1 13 Real power system A kW 3 1025 4 2 14 Reactive power system A kVAR 3 1027 4 3 15 Voltage L12 system B V 3 1029 5 1 16 Voltage L23 system B V 3 1031 5 2 17 Voltage L31 system B V 3 1033 5 3 18 Frequency system B Hz Table 7 9 Modbus addresses for LS 4 floating point data table If no response was obtained from the target LS 4 unit Modbus exception code 0B Gateway target device failed to respond is returned LS 4 remote control data table 4 0001 The LS 4 remote control data table is located in the so called Holding register address block which sometimes is also identified with offset 4 0000 The block can be written to using Modbus function code 16 Write multiple registers or function code 06 Write single register If Remote Control is enabled the three remote control words are sent cyclically to the respective LS 4 They are also stored in the GCP MGs memory and can be read back using Modbus function code 03 Read holding registers Remote control is disabled by default and Modbus exception code 03 Illegal value is returned if a Modbus master tries to access remote control functions for a unit configured as read only Remote control can be enabled on a per unit basis throu
13. 7 1 Supported Modbus function codes uii esee hrarnr qropde ts ii tex DER Babe n tpa iuc 29 7 2 Modbus slave ID relationship sese eren it a vut Pdl dk dO Bec 30 7 3 Modbus exception COUPS aussi mii laxi areire iria rrai ASR RAE bela E ERATE AiE 31 7 4 Modbus addresses for GCP 30 MUX values 1 ctc deeem ER e dee R iua hund 31 7 5 Modbus addresses for SB03 Cat CCM and SC06 MTU MDEC options 34 7 6 Modbus addresses for GCP 30 floating point data table sss 35 7 7 Modbus addresses for GCT 30 remote control i55 icc eise p C PPe bete Rog pid 36 7 8 Modbus addresses for LS 4 MUX values iisacsiendic ecelesie etti m dud dh 37 7 9 Modbus addresses for LS 4 floating point data table ssssssssssss 38 7 10 Modbus addresses for LS 4 remote control 1n pacchetti Br e gib 39 UMGCPMG 0801 About this manual About this manual This manual explains how to install operate and configure a GCP MG This manual is to be used with a GCP MG with firmware version 1 0 Document Conventions Throughout this manual we use the following symbols and typefaces to make you aware of safety or other important considerations A Indicates a potentially hazardous situation that if not avoided could result in death or serious injury Indicates a potentially hazardous situation that if not avoided could result in damage to equipment AN Indicates information that is critical for successful application and und
14. IP address of the GCP MG is 169 254 0 10 which is in the Automatic Private IP Addressing APIPA address range There a several methods of configuring the module s IP address 1 Removing your PC from your corporate network and using a cross over network cable see the section called IP setup using a web browser and a cross over network cable 2 Via the secondary serial port and a terminal program like HyperTerminal see the section called IP setup using HyperTerminal 3 Leaving your PC connected to your corporate network and temporarily changing the IP settings on your PC to match the subnet of the GCP MG see the section called Tem porarily changing the IP settings on your PC In order to connect to the GCP MG via TCP IP your PC must be on same IP subnet as the gateway In most situations this means that the first three numbers of the IP address have to be identical IP setup using a web browser and a cross over net work cable This method applies only to operating systems like Windows which support APIPA Au tomatic Private IP Addressing It also requires your PC to be configured for DHCP If your computer is configured with a static IP address follow the procedure in the section called Temporarily changing the IP settings on your PC 1 Disconnect your PC from your corporate network If your computer is configured for DHCP it should now automatically fall back to use a default IP address from the API
15. LORI DK RANT NUU ASEE EEE EERE ERKE ETRE MEA EPEE 18 5 3 Modbus stat Pare sieniin ree bend pd diu NAM DANN EU EEE EEEE EE E EEEE 19 5 4 CAN communication status page ueqeackias quina RH Re Ida UV ou ERREUR REM UH 21 smog 1010161 a 0V1 M 22 5 6 Ethernet and IP settings pase quasssteneiiveicabien tubo dapa e Errat uu RO bio ater LUE 23 5 7 IP settings changed Confirmation us oa coca coR DK Gre reste QU E TROU CUOI ees 23 5 8 GCP 30 settings page MM X M ss 24 5 9 Mod s settings page 25 5 10 Restart device Pare ssiri enpruntar a E E Ea E aE aE eii aS 26 5 11 Restart confirmation pa e audit pH QA reirei akea REEE RUD LUN ENE EEEn 26 Gl Gateway Operation sssisciriy donoe e aa EE EE ere e aE e 27 9 1 BEnelosure cxmens tons aoo e erede as seis irsims ELM uai Snaren stanar LE e EHE Ean SEERE PRAE e RATER Eiane 42 3 1 Power supply connector pinout uo uen sortet oesi B Cond isa ae EN BPO Rt 7 3 2 CAN connector DIDOBE sses scirki s wire s tirei artistei eina ioiei ER RE Re DRE ena SR UR Er XR tarea in 8 9 9 RS 485 connector DISODUE seses aia ee name 8 3 4 Primary RS 232 Modbus connector pinout ininiinsninnadmnnnuntinndsnn 9 3 5 Ethernet connector PiNOUt serris teisines sr iesse NEE EAER oE RES AEI SELGET 10 3 6 Secondary RS 232 Diagnostic connector pinout eessessserssrsessssissrssrsserssinseeseesse 11 6 1 LED diagnostic COUBS acce ctos RED ties petet rd dis decida eR del Di Op dia ORO acs 28
16. LS4 Modbus Ethernet amp IP Restart Figure 5 1 Device management and configuration via the web browser Gateway IP address 9 Main menu Configuration sub menu UMGCPMG 0801 17 GCP MG Ethernet Modbus gateway User manual O Infomation area Use the menu bar shown on the left side to navigate the different pages R In order to connect to the GCP MG via TCP IP your PC must be on same IP subnet as the gateway In most situations this means that the first three numbers of the IP address have to be identical Monitoring and diagnostic The GCP MG offers several web pages which allow monitoring of the status of the different communication networks and the device performance Device status The Overview page shows the principal device status as shown in the following picture Overview Device Status Device OK CAN Controller ACTIVE Figure 5 2 Overwiew page The value shown in the Device row represents the device status register which keeps track of run time faults All run time faults are latched and must be reset by the user The fol lowing faults can be listed here OK The device is fault free Watchdog reset This warning indicates that the device was reset by it s internal watchdog supervision circuit Brown out reset This warning indicates that the device was reset by it s internal supply voltage moni toring circuit This fault occurs when the supply voltage drops below the lower li
17. alarm 1 3 0055 17 3 54 Internal alarm 2 3 0056 18 1 55 Internal alarm 3 3 0057 18 2 56 Internal alarm 4 3 0058 18 3 57 Internal alarm 5 3 0059 19 1 58 External alarm 1 3 0060 19 2 59 External alarm 2 3 0061 19 3 60 Internal alarm 7 3 0062 20 1 61 Analogue input T1 3 0063 20 2 62 Analogue input T2 3 0064 20 3 63 Analogue input T3 3 0065 21 1 64 Analogue input T4 3 0066 21 2 65 Analogue input T5 3 0067 21 3 66 Analogue input T6 3 0068 22 1 67 Analogue input T7 3 0069 22 2 68 Alarm messages IKD2 SC06 3 0070 22 3 69 LCD display Pickup 3 0071 Not used by a standard GCP 30 reserved for options future expansion or 0100 custom versions See below for allocation by option SB03 and SC06 Table 7 4 Modbus addresses for GCP 30 MUX values If no response was obtained from the target GCP 30 unit Modbus exception code 0B Gateway target device failed to respond is returned UMGCPMG 0801 33 GCP MG Ethernet Modbus gateway User manual Allocation with options SB03 and SC06 Block Modbus GCP 30 GCP 30 SB03 option Cat CCM designator SC06 option MTU MDEC address MUX word no designator 3 0071 23 1 70 Coolant temperature Woodward ST 3 control lambda set point 3 0072 23 2 71 Oil pressure Woodward ST 3 control lambda reading 3 0073 23 3 72 Raw water temperature Woodward ST 3 control actuator po sition 3 0074 24 1 73 Turbo charger intake temperature Engine s
18. are for example messages larger than the allowed maximum PDU size defined in the Modbus standards This can be caused by non Modbus traffic on the network Rx time outs Modbus serial line A counter that increments each time an inter character time out occurred during the reception of an inbound message Rx time outs Modbus TCP A counter that increments if the master connection has timed out Subsequently the connection is terminated by the GCP MG A time out occurs if no Modbus request is received from a connected client within a 10 second period Tx time outs Number time outs occurred when attempting to send a reply message The cumulative diagnostic data is reset when the device is power cycled or reset The data is also reset by pressing the Clear Counter button CAN communication status The CAN status page shows status and statistics about the CAN bus traffic These values provide valuable information used to troubleshoot CAN problems This page is automat ically updated every 5 seconds 20 UMGCPMG 0801 Web browser based management Detailed Status CAN Communication Unit CANId Status Messages Received Messages Sent GCP 30 1 801 OK 68981 19575 GCP 30 2 802 OK 68969 0 GCP 30 3 803 OK 68970 0 GCP 30 4 804 OK 68963 0 GCP 30 5 805 OK 68754 19572 GCP 30 6 806 OK 68732 0 GCP 30 7 807 OK 68658 0 LS 4 1 817 OK 68501 0 LS 4 2 818 OK 68489 0 LS 4 3 819 OK 68485 0 Figure 5 4 CAN
19. communication status page This page shows accumulated readings since the GCP MG was last activated or reset If power to the GCP MG is lost all cumulative values are reset to zero The CAN communication channel between a GCP 30 or LS 4 unit and the GCP MG can be in one of the following states OK The CAN communication channel with the GCP 30 or LS 4 unit has been established The GCP 30 or LS 4 control is cyclically updating data WAIT The presence of a GCP 30 or LS 4 unit has been detected however the GCP MG is cur rently waiting to receive a complete data set It takes approximately between 2 3 and 3 seconds to receive a full data set from the GCP 30 and approximately 10 seconds from the LS 4 TIME OUT No CAN message was received for a period of 1 second A GCP 30 control is supposed to send a CAN message every 100 ms a LS 4 every 200 ms The following statistics are maintained Messages received A counter that increments each time an inbound CAN message matching the shown CAN ID is successfully received Messages sent A counter that is incremented each time a CAN message is sent CAN messages are only sent if Remote Control is enabled for this GCP 30 or LS 4 UMGCPMG 0801 21 GCP MG Ethernet Modbus gateway User manual The cumulative diagnostic data is reset when the device is power cycled or reset The data is also reset by pressing the Clear Counter button Finding the firmware version and serial number
20. port and serial port GND pins which can cause damage to the device Wiring the CAN interface The CAN interface connects to the GCP 30 and LS 4 devices The CAN connector is a male 9 pin D sub type located at the top side of the mounted module refer to Figure 2 1 Location of connectors It has industry standard CiA DS 102 pinout as shown in the following table and picture UMGCPMG 0801 7 GCP MG Ethernet Modbus gateway User manual as Pin Signal Function 38 1 NC 2 CANL CAN L bus line 3 GND CAN ground 4 NC 5 NC 6 GND Optional CAN ground 7 CANH CAN H bus line 8 NC 9 NC FG Connector frame shell is internally connected to ground Table 3 2 CAN connector pinout The bus must be terminated at both ends with its characteristic impedance typically a 120 Ohm resistor The cable must be a twisted pair for CAN H CAN L and a third wire for the ground Maximum number of CAN nodes is 64 e Maximum CAN cable length is 250 m 820 ft e Stub connections off the main line should be avoided if possible or at least be kept as short as possible The cable must be shielded and the shield must be connected to a protective ground at a single point to assure a high degree of electromagnetic compatibility and surge protection The shield must not be connected to the GND pins or the connector shell Wiring the Modbus RS 485 interface The Modbus RS 485 port is used for inte
21. power system Consider all sources of power including the possibility of backfeeding Apply appropriate personal protective equipment and follow safe electrical prac tices Turn off all power supplying the equipment in which the GCP MG is to be installed before installing and wiring the GCP MG e Always use a properly rated voltage sensing device to confirm that power is off Beware of potential hazards wear personal protective equipment and carefully inspect the work area for tools and objects that may have been left inside the equip ment The successful operation of this equipment depends upon proper handling instal lation and operation Neglecting fundamental installation requirements may lead to personal injury as well as damage to electrical equipment or other property Failure to follow these instructions will result in death or serious injury Regulatory notes 1 The GCP MG module is suitable for use in non hazardous locations only 2 The GCP MG module is not authorized for use in life support devices or systems 3 Wiring and installation must be in accordance with applicable electrical codes in accor dance with the authority having jurisdiction 4 The GCP MG is designed for installation into an electrical switchboard or cubical as part of a fixed installation Unpacking and handling 1 Please read this manual carefully before opening the module or fitting it into your sys tem 2 Keep all original packagin
22. 1 3 0024 7 2 23 Generator current in L2 3 0025 7 3 24 Generator current in L3 3 0026 8 1 25 Actual generator reactive power 3 0027 8 2 26 Generator cos phi 3 0028 8 3 27 Current reserve power in the system in KW 3 0029 9 1 28 Current actual real power in the system 3 0030 9 2 29 Number of participants on the CAN bus 3 0031 9 3 30 High byte Mains status Low byte Generator status 3 0032 10 1 31 Exponents 3 0033 10 2 32 Bus bar frequency 3 0034 10 3 33 Configuration T5 T8 3 0035 11 1 34 Mains voltage delta V23 3 0036 11 2 35 Mains voltage delta V31 3 0037 11 8 36 Mains voltage delta V1N 3 0038 12 1 37 Mains voltage delta V2N 3 0039 12 2 38 Mains voltage delta V3N 3 0040 12 3 39 Mains frequency out off VN12 VN23 VN31 3 0041 13 1 40 Mains current in L1 3 0042 13 2 41 Mains reactive power 3 0043 13 3 42 Mains power factor 3 0044 14 1 43 Exponents 3 0045 14 2 44 Exponents 3 0046 14 3 45 Engine operating hours high word 3 0047 15 1 46 Engine operating hours low word 3 0048 15 2 47 Hours until next maintenance 3 0049 15 3 48 Engine start number 3 0050 16 1 49 Operation mode 3 0051 16 2 50 Generator active energy high word 3 0052 16 3 51 Generator active energy low word 32 UMGCPMG 0801 Modbus data organization Block Modbus GCP 30 GCP 30 GCP 30 manual designator address MUX word no 3 0053 17 1 52 Battery voltage 3 0054 17 2 53 Internal
23. 3 1061 17 52 Battery voltage V 3 1063 20 1 61 Analogue input T1 3 1065 20 2 62 Analogue input T2 3 1067 20 3 63 Analogue input T3 3 1069 21 1 64 Analogue input T4 3 1071 21 2 65 Analogue input T5 3 1073 21 3 66 Analogue input T6 3 1075 22 1 67 Analogue input T7 Table 7 6 Modbus addresses for GCP 30 floating point data table GCP 30 remote control data table 4 0001 The GCP 30 remote control data table is located in the so called Holding register address block which sometimes is also identified with offset 4 0000 This block can be written to using Modbus function code 16 Write multiple registers or function code 06 Write single register UMGCPMG 0801 35 GCP MG Ethernet Modbus gateway User manual If remote control is enabled the three remote control words are sent cyclically to the re spective GCP 30 They are also stored in the GCP MG s memory and can be read back us ing Modbus function code 03 Read holding registers Remote control is disabled by default and Modbus exception code 03 Illegal value is returned if a Modbus master tries to access remote control functions for a unit configured as read only Remote control can be enabled on a per unit basis through the GCP 30 settings page of the GCP MG see the section called Configuring GCP 30 and LS 4 Modbus access Block Modbus GCP 30 GCP 30 manual designator Encoding address word no 4 0001 501 Generator real power set point
24. CP MG supports the Modbus function codes 03 04 06 and 16 A maximum of 100 16 bit words can be requested with Modbus command 04 This makes it possible to read the complete data set of a GCP 30 or LS 4 unit with a single Modbus transaction Modbus Function name Access Max number of 16 bit Data table block function code words per transaction 04 Read input registers read 100 3 0000 03 Read holding registers write 3 4 0000 06 Write single register write 1 4 0000 16 Write multiple registers write 3 4 0000 Table 7 1 Supported Modbus function codes The GCP MG emulates a virtual Modbus slave device for each GCP 30 and LS 4 unit con nected to the CAN bus This simplifies management of PLC and SCADA variable tag ta bles as the Modbus start address is identical for all GCP 30 and LS 4 units The following tables show the relation of an individual unit with the Modbus slave ID and the Modbus register range It is of great importance to ensure that there is not two devices with the same Modbus address In such a case an abnormal behavior of the whole serial bus can occur the Master being then in the impossibility to communicate with all present slaves on the bus UMGCPMG 0801 29 GCP MG Ethernet Modbus gateway User manual Unit Modbus Modbus read Modbus write Modbus floating CAN ID slave ID address range address range point address range
25. G 0801 45 This page intentionally left blank 46 UMGCPMG 0801 Index Index A About 22 Accumulative connections 20 ACTIVE 19 APIPA 13 B Baud rate 25 Brown out reset 18 BUS OFF 19 C cable Ethernet 10 RS 232 10 11 RS 485 9 cable length CAN 8 Ethernet length 10 RS 232 9 11 RS 485 9 CAN 7 7 CCM 34 complete update 36 connector CAN 7 Ethernet 10 location 3 power 7 RS 232 9 10 RS 485 8 control 24 CRC errors 20 cross over network cable 13 D Data bits 25 default IP address 13 Device configuration data write failure 19 Device out of memory 18 device status register 18 DIN rail mounting 6 removal 6 disabled 24 E embedded web server 17 enclosure DIN rail clip 3 front cover 3 mounting 6 red hook 6 removal 6 Ethernet 10 23 settings 23 exception codes 31 F faults 18 features 2 Firmware version 22 floating point 34 37 G Gateway address 23 Gateway target device failed to respond 31 GCP 30 21 24 27 29 floating points 35 remote control 36 values 33 H Hardware version 22 HyperTerminal 14 l Ilegal data address 31 Illegal function 31 Illegal value 31 Invalid frames 20 IP settings 13 23 IP address 23 J JavaScript 17 L LED 3 28 line biasing 9 polization 9 LS 4 21 24 27 29 floating points 38 remote control 39 UMGCPMG 0801 47 GCP MG Ethernet Modbus gat
26. L23 system B 3 0018 5 2 17 Voltage L31 system B 3 0019 5 3 18 Frequency system B 3 0020 6 1 19 Exponent 3 0021 6 2 20 Exponent 3 0022 6 3 21 Internal alarms 1 3 0023 7H 22 Internal alarms 2 3 0024 7 2 23 Internal alarms 3 3 0025 7 3 24 Internal alarms 4 3 0026 8 1 25 Internal alarms 5 3 0027 8 2 26 Internal alarms 6 3 0028 8 3 27 Internal alarms 7 3 0029 9 1 28 Internal Diagnosis 3 0030 Not used by a standard LS 4 reserved for future expansion or custom ver 0100 sions Table 7 8 Modbus addresses for LS 4 MUX values If no response was obtained from the target LS 4 unit Modbus exception code 0B Gateway target device failed to respond is returned LS 4 floating point data table 3 1001 The LS 4 floating point data table is located in the so called Input register address block which is sometimes also identified with offset 3 0000 This block is accessed using Modbus Function Code 04 Read input registers UMGCPMG 0801 37 GCP MG Ethernet Modbus gateway User manual The floating point values are encoded in industry standard single precision 32 bit IEEE 754 format The 32 bit floating point values are transmitted as pairs of two consecutive 16 bit registers in little endian word order address word no 3 1001 0 2 2 Voltage L12 system A V 3 1003 0 3 3 Voltage L23 system A V 3 1005 1 4 Voltage L31 system A V 3 1007 1 2 5 Voltage L1N system A V 3 1009 1 3
27. MEN s GCP MG Ethernet Modbus gateway User manual Edition 1 1 October 2008 UMGCPMG 0801 GCP MG Ethernet Modbus gateway User manual Copyright 2007 2008 proconX Pty Ltd All rights reserved Document revision history 2007 05 14 1 0 Initial Release for hardware version J367 S3 PB and firmware version 1 0 2008 07 28 1 1 LED description added Added max number of Modbus TCP connections Cor rected weight Updated company name and address Editorial Changes No part of this material may be reproduced or transmitted in any form or by any means or used to make any derivative work without express written consent from the copyright holders proconX and FieldTalk are trademarks of proconX Pty Ltd All other product and brand names mentioned in this document may be trade marks or registered trademarks of their respective owners Disclaimer proconX Pty Ltd makes no warranty for the use of its products other than those expressly contained in the Company s standard warranty which is detailed in the Terms and Conditions located on the Company s Website The Company assumes no responsibility for any errors which may appear in this document reserves the right to change devices or specifications detailed herein at any time without notice and does not make any commitment to update the information contained herein No licenses to patents or other intellectual property of proconX are granted by the Company in connection with the sale of pro
28. PA range 169 254 x x 2 Connect an Ethernet crossover cable from the GCP MG to the computer 3 Start Internet Explorer 4 In the address box type 169 254 0 10 and then press Enter 5 Click Configuration and then Ethernet amp IP in the menu on the left side of the page 6 Enter the IP address subnet mask and gateway address assigned to your GCP MG then click Save UMGCPMG 0801 13 GCP MG Ethernet Modbus gateway User manual 7 Reconnect your computer to your corporate network IP setup using HyperTerminal 1 Connect a null modem RS 232 cable between your PC and the GCP MG s diagnostic port In Windows XP click Start point to All Programs point to Accessories point to Com munications and then click HyperTerminal When HyperTerminal starts it opens a dialog box and asks for a name for the new con nection Enter a name for example deviceconfig then click OK The Connect to dialog opens Select the COM port you will be using in the Connect using drop down list box then click OK Select 9600 8 None 1 None in the COM Properties dialog then click OK Hyperlerminal is now connected to the serial line Keep the space bar pressed in HyperTerminal and power cycle your device at the same time A menu should appear after one or two seconds showing device information the cur rent IP configuration and a prompt Type SETIP then press Enter within 10 seconds after t
29. Properties Hi Broadcom NetXtreme 57xx Gigabit C This connection uses the following items vi diosn Packet ee F Intemet Td TER M E j BI wa e SEE Description Transmission Control Protocol Intemet Protocol The default wide area network protocol that provides communication across diverse interconnected networks C Show icon in notification area when connected _ Notify me when this connection has limited or no connectivity 3 Select the Internet Protocol TCP IP entry and click on Properties to open the TCP IP Properties dialog as shown below UMGCPMG 0801 15 GCP MG Ethernet Modbus gateway User manual Internet Protocol TCP IP Properties General You can get IP settings assigned automatically if your network supports this capability Otherwise you need to ask your network administrator for the appropriate IP settings Obtain an IP address automatically C Use the following IP address IP address 169 254 0 1 Subnet mask 255 255 0 0 Default gateway Use the following DNS server addresses Preferred DNS server Altemate DNS server 4 Write down your current settings so they can be restored later 5 Select Use the following IP address and configure a static IP address in the same subnet as the device for example 169 254 0 1 and the subnet mask 255 255 0 0 Click OK to save the changes 6 Start Interne
30. VO 35 mm DIN rail EN 60715 IP 20 NEMA Type 1 3 81 mm 2 pin pluggable terminal block header Mini Combicon 10 30 V DC 30 mA typical 24 V DC 750 mW 0 to 60 C 32 to 140 F 25 to 85 C 13 to 185 F 10 to 9596 non condensing Free from corrosive gas minimal dust 101 x 22 5 x 120 mm 3 98 x 0 886 x 4 72 in 0 13 kg 0 287 Ib OOQOO 101 0 mm 3 98 in 120 0 mm 4 72 in Figure 8 1 Enclosure dimensions _ 22 5 mm 0 89 in 42 UMGCPMG 0801 References References GCP30 Woodward Governor Company GCP 30 Series Packages Genset Con trol Configuration Manual 37365A February 2007 LS4 Woodward Governor Company LS 4 Cir cuit Breaker Control Manual Manual 37105A May 2004 UMGCPMG 0801 43 This page intentionally left blank 44 UMGCPMG 0801 Glossary Glossary 10BASE T 10 Mbit s twisted pair Ethernet standard Standardized in IEEE 802 3i APIPA Automatic Private IP Addressing CAN Controller area network Standardized in ISO 11898 CiA DS 102 Standard for the pinout of CAN connectors DCE Data communications equipment DTE and DCE devices have different pinouts for RS 232 connectors A Modem for example is a DCE DIN rail 35 mm wide mounting bracket standardized in DIN EN 50022 DTE Data terminal equipment DTE and DCE de vices have different pinouts for RS 232 con nectors A PC for example is a DTE EIA 232 Sta
31. conX products expressly or by implication proconX products are not authorized for use as critical components in life support devices or systems Support amp product feedback We provide an electronic support and feedback system for our proconX products It can be accessed through the following web link http www proconx com support Your feedback and comments are always welcome It helps improving this product Contact For further information about the GCP MG product or this document please contact us at proconX Pty Ltd PO Box 791 Sumner QLD 4074 Australia Website http www proconx com gcpmg Contents About this manual t v MEO COU eraren eTe 1 FeatUrE M M M 2 2 Description M siht irriki aono dents PREE EEE EE AE EEEE EE EREA 3 Carli MM X 5 Safety precautions RM NN 5 Reg latory NOtES sssri E ERRAR 5 Unpacking andi handling dusscdiusei rtm vett viseurteasaanbantcncacnasatubinseneeieatasauanvmedenaatns 5 Before connecting anything iso ceo adire iain anon 6 DIN rail mounting and TemOVal 22st rb rat e svonntneatevnsesasiuenvonivgersdaonsuso ET Re UID 6 ISERIES NNNM TH 7 Pow ring the GCP MO sirisser insasi nem etin a cU buic UN UM nA Re ENET dU 7 Wiring The CAN TOES oto acaba bebo pad pH uU D ende SEKNE Ere UR D DIU aie 7 W
32. ctor shell To connect the GCP MG to a PC Personal Computer or any other device with data terminal equipment DTE pinout you need a null modem or cross over cable Connecting Ethernet The following table describes the 10BASE T Ethernet RJ 45 connector pinout I I I IT IT Pin Signal Function ee 1 TX Non inverting transmit signal Ud 2 TX Inverting transmit signal 3 RX Non inverting receive signal 4 Internal termination network 5 Internal termination network 6 RX Inverting receive signal 7 Internal termination network 8 Internal termination network FG Connector frame shell is internally connected to ground Table 3 5 Ethernet connector pinout e We recommend to use Category 5 shielded twisted pair network cable e Maximum cable length is 100 m 3000 ft The network cable must be shielded and the shield must be connected to a protective ground at a single point to assure a high degree of electromagnetic compatibility and surge protection The shield must not be connected to the connector frame Connecting to the diagnostic port The module s secondary RS 232 port is used as Diagnostic port and only active power up of the device It allows configuration of the IP settings and reset of the settings to factory defaults via a terminal program The Secondary RS 232 Diagnostic port connector is a male 9 pin D sub type located at the bottom side of the mounted module
33. e check that the GCP 30 unit has been parameterized according ly otherwise the messages sent by the GCP MG are ignored by the GCP 30 Refer to chapter Interface in your GCP 30 Series Genset Control manual For Remote Control to 24 UMGCPMG 0801 Web browser based management work GCP 30 parameter 120 Control via COM X1X5 must be turned on and discrete input Automatic 2 terminal 5 must be asserted If remote alarm acknowledgment is required GCP 30 parameter 122 Ackn F2 F3 via COM interf must be turned on in addition monitored control Similar to control but in addition the remote control is monitored and a Modbus muster must cyclically update the remote control words by writing to the remote con trol data table If a Modbus master fails to do this within a certain time limit the GCP MGwill trigger an Interface error X1X5 alarm on the GCP 30 For Monitored Control to be effective GCP 30 Parameter 121 Supervision X1X5 must be turned on Once you click Save the new settings are stored and applied instantly A confirmation mes sage is shown Configuring serial line Modbus The Modbus settings for serial line can be configured to match the network configuration of your Modbus master device Select the Configuration Modbus sub menu from the menu bar to open the Modbus settings which are shown below Configuration Modbus Serial Port 0 Settings Physical Layer Transmission Mode Baud Rate Data Bits Stop Bits Pant RS 485
34. erstanding of the product N Provides other helpful user information that does not fall in above categories Q Provides supplemental user information Acronym This typeface is used to introduce acronyms or product names Command This typeface is used to represent commands prompts input fields and filenames In the context of programming it is used for functions variable names constants or class names Placeholder This typeface is used to represent replacable text Replaceable text is a placeholder for data you have to provide like file names or command line arguments User input This typeface is used to represent data entered by the user or buttons Screen output Screen output or program listing UMGCPMG 0801 V This page intentionally left blank vi UMGCPMG 0801 Introduction Chapter 1 Introduction The GCP MG is anext generation Modbus CAN gateway specifically designed to interface Woodward s GCP 30 Series Genset Controls and LS 4 Circuit Breaker Controls with Modbus networks The GCP MG gateway has been developed in cooperation with Woodward to ensure the highest possible degree of interoperability with Woodward equipment The gateway features CAN serial RS 232 and RS 485 ports as well as an Ethernet port and can be mounted on a DIN rail On the CAN side it implements the Woodward CAL protocol to connect to the GCP controls On the serial ports and on Ethernet it implements a Modbus server Modbus RTU and M
35. eway User manual values 37 M MAC address 23 MDEC 34 Messages received 21 Messages sent 21 Modbus address range 29 exception codes 30 function codes 29 GCP floating points 35 GCP remote control 36 GCP values 33 LS 4 floating points 38 LS 4 remote control 39 LS 4 values 37 register layout 29 SB03 values 34 SC06 values 34 settings 24 25 slave ID 29 status 20 mounting 6 rules 7 N network mask 23 nodes maximum CAN 8 RS 485 9 P Parity 26 PASSIVE 19 Physical layer 25 pinout CAN 7 Ethernet 10 power 7 RS 232 9 10 RS 485 8 poll rates 31 36 power 7 Product name 22 R read only 24 remote control 35 38 remote restart 26 removal 6 Replies 20 Requests 20 Reset to factory defaults 19 restart 26 RJ 45 10 RS 232 9 10 RS 485 8 run time faults 18 Rx time outs 20 S SB03 34 SC06 34 Serial number 22 settings Ethernet 23 IP 13 23 Modbus 25 shield 8 9 10 10 11 Specifications 41 Stop bits 25 Stub connections 8 9 Subnet mask 23 supply voltage 7 T TCP status 20 temperature operating 7 termination CAN 8 RS 485 9 TIME OUT 21 Transmission mode 25 twisted pair 9 Tx time outs 20 U update cycles 31 W WAIT 21 Watchdog reset 18 Watchdog reset alarm 26 48 UMGCPMG 0801
36. g material for future storage or warranty shipments of the module UMGCPMG 0801 5 GCP MG Ethernet Modbus gateway User manual 3 Do not exceed the specified temperatures Before connecting anything 1 Before installing or removing the module or any connector ensure that the system pow er and external supplies have been turned off 2 Check the system supply voltage with a multimeter for correct voltage range and po larity 3 Connect the power supply cable and switch on the system power Check if the Power LED is lit 4 Turn off system power 5 Connect all I O cables 6 Once you are certain that all connections have been made properly restore the power DIN rail mounting and removal The GCP MG gateway is designed to be mounted on a 35 mm DIN rail according to DIN EN 50022 The enclosure features a 35 mm profile at the back which snaps into the DIN rail No tools are required for mounting Please observe the rules outlined in the section called Mounting rules To mount the module on a DIN rail slot the top part of the GCP MG into the upper guide of the rail and lower the en closure until the bottom of the red hook clicks into place DIN rail To remove the GCP MG from the DIN rail use a screw driv er as a lever by inserting it in the small slot of the red hook i and push the red hook downwards Then remove the mod ule from the rail by raising the bottom front edge of the en closure
37. gh the LS 4 settings page of the GCP MG see the section called Configuring GCP 30 and LS 4 Modbus access 38 UMGCPMG 0801 Modbus data organization Block Modbus LS4 LS4 manual designator Encoding address word no 0001 501 not used for LS 4 0002 502 not used for LS 4 0003 503 Control word Bit 1 1 Open CB high priority Bit 2 1 Close CB Bit 3 write always 0 Bit 4 write always 0 Bit 5 1 Alarm Acknowledgment Bit 6 16 internal use Table 7 10 Modbus addresses for LS 4 remote control If no response was obtained from the target LS 4 unit Modbus exception code 0B Gateway target device failed to respond is returned UMGCPMG 0801 39 This page intentionally left blank 40 UMGCPMG 0801 Specifications Chapter 8 Specifications Modbus Gateway for GCP 30 GCP MG Interfaces Ethernet Serial ports CAN User interface LED indicators Monitoring amp configuration Diagnostic High availability features CAN port Connector Physical layer Isolation Speed Max number of nodes Protocols RS 485 Modbus port Connector Physical layer Isolation Speed Max number of nodes Protocols RS 232 Modbus port Connector Physical layer Isolation Signals Speed Protocols RS 232 diagnostic port Connector Physical layer Isolation Signals Speed Protocols Ethernet port Connector Physical amp Data Link Layer Layer Isolation Speed Max
38. grating the GCP MG into a two wire Modbus over Serial Line network The GCP MG is a Modbus slave device The RS 485 signals are located at the 3 81 mm 6 pin pluggable terminal block Phoenix Contact Mini Combicon type MC1 5 2 ST 3 81 on the top side of the mounted module refer to Figure 2 1 Location of connectors The following table and picture shows the pinout zls Pin EIA 485 Name Modbus name Description 191a C C Common Signal common GND B B D1 Non inverting transceiver terminal 1 RX TX A A DO Inverting transceiver terminal 0 RX TX Signal common GND Reserved for 2nd port must be left unconnected 0 a A j N Reserved for 2nd port must be left unconnected Table 3 3 RS 485 connector pinout 8 UMGCPMG 0801 Installation The bus must be terminated at both ends with its characteristic impedance typically a 120 Ohm resistor The bus lines are to be biased polarized at one point typically at the master connection The cable must be a twisted pair for B A and a third wire for the common Maximum number of RS 485 nodes without repeater is 32 Maximum cable length to 1200 m 4000 ft Stub connections off the main line should be avoided if possible or at least be kept as short as possible To assure a high degree of electromagnetic compatibility and surge protection the RS 485 cable must be shielded and the shield must be connected to a protective ground
39. he prompt is shown deviceconfig HyperTerminal e m BA 169 254 0 10 Subnet Mask 255 255 0 0 Gateway Address SETIP IP Address 169 254 0 10 1 Subnet Mask 255 255 0 0 2 Gateway Address 0 0 0 0 0 RUN MODE 0 0 0 100 939 299 299 0 0 0 0 lt Connected 0 05 24 Auto detect 9600 8 N 1 10 The device will show current values and prompt for new values for IP address net mask and gateway address Enter the new values and press Enter A key press must be received at least every 10 seconds otherwise the device will go back to RUN MODE and resume normal operation 14 UMGCPMG 0801 Ethernet amp IP configuration 11 The gateway will return to the main prompt Type X and press Enter to leave DIAG MODE and resume normal operation indicated with RUN MODE Temporarily changing the IP settings on your PC This method involves manually assigning an IP address to your PC in the same subnet as the gateway The default subnet of the gateway is 169 254 0 0 16 1 Connect the GCP MG to your Ethernet network 2 On a Windows PC open the Control Panel and double click on Network Connections Right click on the Network Connection associated with your network adapter and select Properties LAN or High Speed Internet L 4 Status Repair Bridge Connections Create Shortcut Rename Properties This will show the Local Area Connection Properties Dialog l Local Area Connection
40. iring the Modbus RS 485 interface o odassocile des pe b obret le Genske bau uote HR Pug e 8 Wiring the Modbus RS 232 interface aivsseierdidue hiebst et rtes iro re tati dlc break e tbt re rbnad 9 Connecting Ethernet iisisti ea aaa eea a eade VeSa AES EN 10 Connecting to the diagnostic port s sssssssesssrsesissesesresesenresseseesensesnestsnesrensenees 10 d Ethernet amp IP configurato imasi tin wescnsssiveidesencnaeanvetate quimuassssbauvesinmsidvnitetimesenunnmegeiens 13 IP setup using a web browser and a cross over network cable 13 IP setup using HyperTerminal usado oec cords ab iee ia a nian 14 Temporarily changing the IP settings on your PC uiuere sert nbtes pisci 15 b Web browser based management siccccaneiisninorecatece P Pon NUR ca ROG REMO RUDI ERR E VUE de 17 Connecting fo the GCP MG aset bue as tesneni DER E CHA ed nE E hot as nee 17 Monitoring and dia nOshC sisihna ar centenarians 18 Device SAL US asnzesssossccpncasssvassnssncvcerdceseniensinnnsaevecsvssncoigetanenesvnpicarteteonarinrmane 18 CAN communication SES sisisi enis reiii s ai nis Ee 20 Finding the firmware version and serial number oerte 22 Configuring and commissioning secco e toin sad tun o aede uerb koi rce cuis De rd vnd pA MERE 22 Contouring Ethernet and IP Lose ceb o PUEMAR cb A acp Ga Rvtb E E ie ON SUD D 22 Configuring GCP 30 and LS 4 Modbus access rere ter trien enne 24 Contie rine serial line MOODUSisc cin ttr rri pn
41. kW with control argument 4 0002 502 Generator power factor set point cos phi x 100 4 0003 503 Control word Bit 1 1 Remote start Bit 2 1 remote stop high priority Bit 3 write always 0 Bit 4 write always 0 Bit 5 1 Alarm acknowledgment Bit 6 16 internal use Table 7 7 Modbus addresses for GCP 30 remote control If no response was obtained from the target GCP 30 unit Modbus exception code 0B Gateway target device failed to respond is returned LS 4 MUX data table 3 0001 The LS 4 MUX data table contains all data values a LS 4 is transmitting cyclically on the CAN bus A LS 4 sends a value every 200 ms Therefore it takes approximately 10 seconds for a complete update of the data table with new values from the CAN bus The data table can be polled much faster by a Modbus master however faster poll rates would not offer higher update cycles The LS 4 MUX data table is located in the so called Input register address block which sometimes is also identified with offset 3 0000 The block is accessed using Modbus func tion code 04 Read input registers Only Modbus address 0001 can be accessed at all times All other Modbus addresses can only be accessed if the CAN communication between GCP MG and LS 4 has been estab lished If this is not the case a Modbus exception code 0B Gateway target device failed to respond is returned indicating the LS 4 unit is not present on the CAN bus For the LS 4 MUX data tab
42. le the GCP MG acts as a transparent gateway between the LS 4 unit and the Modbus Except for the device status register at Modbus address 0001 it does not perform any modification to the representation of the data values The Woodward LS 4 Circuit Breaker Controls manual LS4 is the ultimate reference for the encoding and representation of the data values Please refer to the Transmission telegram table in Appendix E Interface of this manual for further details 36 UMGCPMG 0801 Modbus data organization The following table shows the relationship between Modbus addresses and the so called MUX identifiers or word numbers Block Modbus LS 4 MUX LS4 LS 4 manual designator address word no 3 0001 n a n a CAN device status register Bit 1 1 CAN communication between GCP MG and LS 4 OK Bit 2 16 reserved for future use 3 0002 0A 1 Protocol number 1600 3 0003 0 2 2 Voltage L12 system A 3 0004 0 3 3 Voltage L23 system A 3 0005 1 1 4 Voltage L31 system A 3 0006 1 2 5 Voltage L1N system A 3 0007 1 3 6 Voltage L2N system A 3 0008 2 1 7 Voltage L3N system A 3 0009 2 2 8 Frequency system A 3 0010 2 3 9 Current L1 system A 3 0011 3 1 10 Current L2 system A 3 0012 3 2 11 Current L3 system A 3 0013 3 3 12 Power factor 3 0014 4 1 13 Real power system A 3 0015 4 2 14 Reactive power system A 3 0016 4 3 15 Voltage L12 system B 3 0017 5 1 16 Voltage
43. mit Device out of memory This warning indicates that the internal dynamic memory has been exhausted and due to this a certain function could not be completed 18 UMGCPMG 0801 Web browser based management Device configuration data write failure This alarm indicates that the configuration data could not be written to the non volatile memory Configuration data changes will be lost once the device is power cycled or reset Reset to factory defaults This alarm indicates that the device configuration data was reset to factory defaults The device requires re commissioning The CAN controller status indicates the status of the CAN interface and can be in one of the following states ACTIVE The CAN bus is fault free PASSIVE CAN s built in fault confinement mechanism has set the node to error passive state due to a large number of errors on the CAN bus This warning indicates a wiring error BUS OFF CAN s built in fault confinement mechanism has set the node to bus off state due to excessive errors on the CAN bus This alarm indicates a wiring error The GCP MG will not transmit or receive any message on the CAN bus once entered this state The device needs to be manually restarted on order to recover from this fault The Modbus Status page shows status and statistics about the Modbus traffic These values provide valuable information used to troubleshoot Modbus network problems This page is automatically updated every 5 second
44. mitting cyclically on the CAN bus A GCP 30 sends a value every 100 ms Therefore it takes approximately between 2 3 and 3 seconds for a complete update of the data table with new values from the CAN bus The data table can be polled much faster by a Modbus master however faster poll rates would not offer higher update cycles The GCP 30 MUX data table is located in the so called Input register address block which sometimes is also identified with offset 3 0000 The block is accessed using Modbus func tion code 04 Read input registers Only Modbus address 0001 can be accessed at all times All other Modbus addresses can only be accessed if the CAN communication between GCP MG and GCP 30 has been es tablished If this is not the case Modbus exception code 0B Gateway target device failed to respond is returned indicating the GCP 30 is not present on the CAN bus For the GCP 30 MUX data table the GCP MG acts as a transparent gateway between the GCP 30 unit and the Modbus Except for the device status register at Modbus address 0001 it does not perform any modification to the representation of the data values The Woodward GCP 30 Series Genset Control manual GCP30 is the ultimate reference for the encoding and representation of the data values Please refer to the Transmission Telegram table in Appendix C Interface Control of this manual for further details The following table shows the relationship between Modbus addresses and the
45. ndard for serial transmission of data be tween two devices also known as RS 232 and V 24 EIA 422 ANSI TIA EIA 422 standard for serial trans mission of data between two devices also known as RS 422 and V 11 EIA 485 ANSI TIA EIA 485 standard for serial trans mission of data between multiple devices al so known as RS 485 EIA 574 Standard for the pinout of serial D sub con nectors ESD Electrostatic discharge ESD can damage electronic equipment IEEE Institute of Electrical and Electronics Engi neers IP Ingress Protection Rating standardized in IEC 60529 Standard for various grades of electrical enclosures ISO International Standards Organisation MAC address Every piece of Ethernet hardware has a unique number assigned to it called it s MAC address MAC addresses are administered and assigned by the IEEE organization Modbus Fieldbus protocol used in the process au tomation industry It uses a master and slave structure Originally developed by Modicon now part of Schneider Automation NEMA National Electrical Manufacturers Associa tion NEMA defines standards for various grades of electrical enclosures Node A communications device on the network PC ABS Polycarbonate ABS Widely used thermo plastic material PLC Programmable Logic Controller RS 232 See EIA 232 RS 422 See EIA 422 RS 485 See EIA 485 UL 94 Plastics flammability standard released by Underwriters Laboratories of the USA UMGCPM
46. ning range is reserved for future expansion of the LS 4 or custom versions If no response was obtained from the target GCP 30 unit Modbus exception code 0B Gateway target device failed to respond is returned The following table lists the Modbus exception responses sent by the gateway instead of a normal response message in case of an error 30 UMGCPMG 0801 Modbus data organization Modbus Exception name Reason exception code 01 Illegal function A Modbus master sent a Modbus function which is not supported by the gateway Please refer to the documentation of the individual data tables for valid function codes 02 Illegal data address A Modbus master queried a non existing Modbus address or the queried range points outside of a data table Please refer to the docu mentation of the individual data tables for valid address ranges 03 Illegal value A Modbus master sent a Modbus message which s structure or implied length is invalid Also returned if a Modbus master tries to access re mote control functions for a unit configured as read only 0B Gateway target device A Modbus master tries to access data which is unavailable because no failed to respond response was obtained from the target GCP 30 or LS 4 unit Usually means that the unit is not present on the CAN bus Table 7 3 Modbus exception codes GCP 30 MUX data table 3 0001 The GCP 30 MUX data table contains all data values a GCP 30 is trans
47. odbus TCP and accepts connections from Modbus master devices like PLCs and SCADA systems Usage and configuration of the gateway is simple and conveniently performed using a web browser which connects to the embedded web server Figure 1 1 GCP MG mounted on DIN rail Possible areas of application are PLC connection Operator panel interfacing HMIs SCADA integration Power station automation Gen set control Remote control amp monitoring Data logging UMGCPMG 0801 1 GCP MG Ethernet Modbus gateway User manual Features The GCP MG GCP MG gateway provides the following key features Modbus TCP protocol Ethernet Modbus RTU protocol either RS 232 or RS 485 software configurable Interfaces with up to 16 GCP 30 controls and up to 8 LS 4 controls Full support of Option SB03 Cat CCM and Option SC06 MTU MDEC GW4 backward compatible Modbus register layout Dedicated Modbus slave ID for each GCP 30 and LS 4 control Complete data set of one GCP 30 unit can be read with a single Modbus transaction Integer Exponent value pairs for voltages power and currents are additionally repre sented as 32 bit floating point registers Serial baud rate up to 115200 bps Support of Modbus function codes 03 04 06 and 16 Concurrently one Modbus serial line and up to two Modbus TCP connections Embedded web server for easy configuration and commissioning using a web browser Firmware upgradeable via Ethernet DIN rail mountable
48. peed 3 0075 24 2 74 Oil temperature Oil pressure 3 0076 24 3 75 Intake manifold temperature Alarm code 3 0077 25 1 76 Throttle position Operating hours 3 0078 25 2 77 Engine speed Coolant temperature 3 0079 25 3 78 Multiplexed ECU alarms 1 Oil temperature 3 0080 26 1 79 Multiplexed ECU alarms 2 Fuel temperature 3 0081 26 2 80 Multiplexed ECU alarms 3 Speed reply 3 0082 26 3 81 Multiplexed ECU alarms 4 Multiplexed ECU alarm group 1 3 0083 27 1 82 Multiplexed ECU alarm group 2 3 0084 27 2 83 Reserved MDEC bit 11 3 0085 27 3 84 Reserved MDEC bit 12 3 0086 28 1 85 Reserved MDEC bit 13 3 0087 28 2 86 Reserved MDEC bit 14 3 0088 28 3 87 Reserved MDEC bit 15 3 0089 29 1 88 Reserved MDEC bit 16 3 0090 29 2 89 Reserved MDEC bit 17 3 0091 29 3 90 Reserved MDEC bit 18 Table 7 5 Modbus addresses for SB03 Cat CCM and SC06 MTU MDEC options GCP 30 floating point table 3 1001 The GCP 30 floating point data table is located in the so called Input register address block which is sometimes also identified with offset 3 0000 This block is accessed using Modbus function code 04 Read input registers The floating point values are encoded in industry standard single precision 32 bit IEEE 754 format The 32 bit floating point values are transmitted as pairs of two consecutive 16 bit registers in little endian word order 34 UMGCPMG 0801 Modbus data organization
49. ration Restart Device Pressing the button below will perform a restart of the device Figure 5 10 Restart device page Click on the Restart button to perform a restart of the device The restart is confirmed with the following notification Configuration Device has been reset Please wait a few seconds for it to restart before continuing Continue Figure 5 11 Restart confirmation page Please allow a few seconds before continuing working with the device as it has to fully start up first before being able to respond to further web browser requests After a remote restart a Watchdog reset alarm is shown on the device home page This is a side effect of the remote restart procedure and the alarm shall be ignored and cleared 26 UMGCPMG 0801 Gateway operation Chapter 6 Gateway operation This chapter describes the principal operation of the gateway The GCP MG establishes a communication channel to each GCP 30 and LS 4 unit connect ed to the CAN bus All GCP 30 and LS 4 units transmit multiplexed data values which the GCP MG stores in its internal data tables A GCP 30 for example sends a new value every 100 ms a LS 4 every 200 ms The GCP MG acts as a Modbus server on Ethernet and the serial interface It accepts con nections and Modbus queries from Modbus master devices The Modbus registers are then served from the GCP MG s internal data tables Because of the data table buffering the
50. retos ie bailar ER Re 25 Remote restarting the CeVICB aues otav dis caesi Do doce 26 b Gateway Operation sores mein prit or Pakeen uu KR er prp p REED E E 27 LED SCANS MT 28 7 Modbus data orgqiiizabtOE ing anise petebran eei prit auetehtanneiariaupiuntsannednpinneiteiasancderitemaatasneiarns 29 GCP 30 MUX data fable 3 0001 scion didt sie a Rino Eid pu tien Eu ient oe Papa ud aena 31 Allocation with options SB03 and BGUD iiid scies erint ha rie a REL nU HR 34 GCP 30 floating point table 3 1001 uode et Genel a cn iin Da S e uta 34 GCP 30 remote control data table 4 0001 5a ott erp E tritt ub bi PLE MERE e PER dne 35 L5 4 MUX dala fable 3 0001 asiste Et ERU ERA MORBI eM Se PNE UD UE 36 LS 4 floating point data table 3 1001 12st rookie n Br anne dine 97 LS 4 remote control data table 4 0001 uiis aos stator inerat na etai Ra beo tabs 38 jer wii 1O 9 REM 41 Dimensions ioo epar m Rl ee eee EM Dp EIU DEM lear 42 liz C E 43 CIIOSSBEY cerasina A e a iba tesi cei GEL pae Sd n epu det Pai Ee bei f 45 ll 47 UMGCPMG 0801 lii Figures Tables 1 1 GCP MG mounted on DIN rail s scsosssiueunreseprseniavndboss hens basantpoann cian sorbaepiaues Ebor beeenereshes 1 2 1 Location Of COMME EONS PM amen LEANA EEAS EEEE SEEE 3 5 1 Device management and configuration via the web browser ssessses 17 Bo OVER WIEW pa p sorrisi sneis tr
51. rmed The following table outlines the indicator condition and the corresponding status after the power on self test has been completed LED Function Condition Indication Power Power Off No power applied to the device Green Power supply OK Link Ethernet link Off No Ethernet link Green Ethernet link OK Status1 Device status Off The device has an unrecoverable fault may need replacing Flashing green at 1s Device operational but needs commissioning due to configuration rate missing incomplete or incorrect Green The device is operating in normal condition Flashing red at 1 s rate Device operational but has a fault listed which requires acknowl edgment Red The device has an unrecoverable fault may need replacing Flash ing sequence and rate of Status2 LED indicates fault class Status2 Modbus CAN Off CAN connection OK Connection time out on Modbus status Green Both Modbus and CAN connection OK Flashing red green at 1 s rate Flashing red at 1 s rate Modbus connection OK Connection time out on CAN Connection time out on both CAN and Modbus Red Table 6 1 LED diagnostic codes The device has detected an error that has rendered it incapable of communicating on CAN 28 UMGCPMG 0801 Modbus data organization Chapter 7 Modbus data organization This chapter describes how GCP 30 and LS 4 data values are organized in logical blocks and accessed via Modbus The G
52. rnet parameters are shown MAC address The device unique MAC address This number is hard coded and cannot be changed The following Internet protocol IP settings can be entered IP address The IP address assigned to this device Subnet mask also known as network mask If you have a router enter the subnet mask for the segment to which this device is attached Gateway address If your network segment has a router enter its IP address here Otherwise leave the address as 0 0 0 0 Once you click Save the new settings are stored and applied instantly The new settings are confirmed with the following page Your network configuration has been changed The IP address is now 169 254 0 10 Please click the button below to redirect your browser to the new IP address Go to New IP Address Figure 5 7 IP settings changed confirmation Please write down the new IP address so you are able to communicate with the device in the future UMGCPMG 0801 23 GCP MG Ethernet Modbus gateway User manual Configuring GCP 30 and LS 4 Modbus access Access from the Modbus to a GCP 30 and LS 4 unit can be configured on a per unit basis You have the option of completely disabling a gen set control for Modbus access have read only access or enabling remote control either unsupervised or time out supervised To configure the Modbus access enter the Configuration sub menu and click on either the GCP 30 or LS 4 menu entry
53. s Detailed Status Modbus Serial Line Port Requests Replies CRC Errors Invalid Frames Rx Time outs 74 74 0 0 0 Modbus TCP Slot TCP Status Accumulative Requests Replies Invalid Frames Rx Time outs Tx Time outs Connections LISTEN 0 0 0 0 0 0 1 169 254 0 111 0 332 332 0 0 0 Figure 5 3 Modbus status page This page shows accumulated readings since the GCP MG was last activated or reset If power to the GCP MG is lost all cumulative values are reset to zero The following statistics are maintained UMGCPMG 0801 19 GCP MG Ethernet Modbus gateway User manual TCP status Status of the TCP IP connection as per TCP finite state machine refer to RFC 793 If no client is connected the status indicates LISTEN If a client is connected it s IP address is shown Accumulative connections A counter that increments each time a client opens a Modbus TCP connection Requests A counter that increments each time an inbound request message is successfully re ceived Replies A counter that is incremented each time a reply message is sent back to the master This includes exception replies CRC errors A counter that increments each time a message is received that has a CRC that does not match what is calculated Typically the result of wiring issues Messages with CRC errors are discarded and not replied to Invalid frames A counter that increments each time a malformed Modbus frame is detected Mal formed frames
54. so called MUX identifiers or word numbers Block Modbus GCP 30 GCP 30 GCP 30 manual designator address MUX word no 3 0001 n a n a CAN device status register Bit 1 1 CAN communication between GCP MG and GCP 30 OK Bit 2 16 reserved for future use 3 0002 0 1 1 Generator voltage delta V12 3 0003 0 2 2 Generator frequency f 3 0004 0 3 3 Actual generator real power P 3 0005 1 1 4 Exponents 3 0006 1 2 5 Real power set point value 3 0007 1 3 6 Conversion factor steps to kW UMGCPMG 0801 31 GCP MG Ethernet Modbus gateway User manual Block Modbus GCP 30 GCP 30 GCP 30 manual designator address MUX word no 3 0008 2 1 7 Bus bar voltage delta V12 3 0009 2 2 8 Mains voltage delta V12 3 0010 2 3 9 Currently present alarm class 3 0011 3 1 10 Control register 2 3 0012 3 2 11 Actual mains interchange import export real power 3 0013 3 3 12 Control register 1 3 0014 4 1 13 Alarm message IKD SC06 3 0015 4 2 14 Internal alarm 6 3 0016 4 3 15 Generator voltage delta V23 3 0017 5 1 16 Generator voltage delta V31 3 0018 5 2 17 Generator voltage delta VIN 3 0019 5 3 18 Generator voltage delta V2N 3 0020 6 1 19 Generator voltage delta V3N 3 0021 6 2 20 Configuration T1 T4 3 0022 6 3 21 Engine speed measured via the Pickup 3 0023 7 1 22 Generator current in L
55. t Explorer 7 In the address box type 169 254 0 10 and then press Enter 8 Click Configuration and then Ethernet amp IP in the menu on the left side of the page 9 Enter the IP address subnet mask and gateway address assigned to your GCP MG then click Save 10 Restore your computer s original settings 16 UMGCPMG 0801 Web browser based management Chapter 5 Web browser based management The GCP MG incorporates an embedded web server This allows you to connect to the device and monitor and configure it using a web browser Most browsers should work provided they support JavaScript We recommend Internet Explorer 6 0 or higher Connecting to the GCP MG Once you made sure that your PC is configured to be on the same subnet as the GCP MG start your web browser In the address box type the IP address of your device 169 254 0 10 is the default and then press Enter See Chapter 4 Ethernet amp IP configuration The web browser will establish communication with the embedded web server and an overview page similar to the following picture will appear proconX GCP Modbus Gateway Windows Internet Explorer oE BAR Go Y le http 169 254 0 10 x 44 x e Sea AE we od proconX GCP Modbus Gateway em dh Page Gp Tools GGE Modbus Gateway Menu Overview 2 Overview Modbus Status Device Status CAN Status Device OK About CAN Controller W W ACTIVE GCP 30 3
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