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Monico CDL Specifications

1. R7 Protocol 1 AB Tag Names ey Protocol 2 Discovery Method Automatic T Protocol 3 i Scan From 38 Services none IF T T Th cin SEGUE cer dux ae caf CAT Link Option Card CAT Link Interface CAT Data Link Fault Codes Em CDL v Collect Fault Data Fetch Fault Details l Clear Port Settings dd Additional Device Figure 7 1 Collect Fault Data If only COLLECT FAULT DATA is checked it will cause the following fault data to be collected MID Module Identifier of the diagnosing controller CID Component Identifier of the fault device FMI or SubCode Fault Mode Identifier showing the severity of the fault Flags Indicates whether the codes is Event or Diagnostic Code and whether it is Active or not If FETCH FAULT DETAILS is also checked the driver will also collect the following information for each fault code OCCURENCES Number of times this code has occurred FIRST First occurrence in engine operating hours LAST Last occurrence in engine operating hours In figure 7 2 below you can see a block of fault data collected without Fault Details and mapped to Allen Bradley Tag Names as an example As you can see in this figure Faultsource MID Faultcode CID Faultsubcode FMI or Sub Code FaultFlags Shows whether it is a Diagnostic Code or Event Code Bit7 and whether the code is currently ACTIVE Bit0 If Bit7 of this value is high then it is a Diagnostic code If low then it is an Event
2. Not Avail Not Avail Not Avail Not Avail Not Avail Not Avail Not Avail Not Avail Not Avail Not Avail Not Avail Hex Real DB1003 0072 LONG CDL 257 GeneratorTotalKVARHours Not Avail lt Status Reading Data Update Count is 415 Close Figure 6 8 Live Block Viewer Parameter Status Block A special device named PIDStatus Values is usually installed under the Programming RS 232 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 X Xxx indicates the current action in the driver Consult the factory for details of this parameter if you are experiencing difficulties The right hand character xx XX indicates the controller which is currently providing the parameter PLEASE NOTE THIS DOES NOT NECESSARILY MEAN YOU WILL HAVE A VALUE IN THE PARAMETER It simply means that at least one controller on the engine network is responding to the request for that specific parameter If you have any issues with a particular parameter it is a good idea to record this status value for use by the factory in troubleshooting Any parameter with a value in the right hand hex character should be available in your installation However if the appropriate sensor is not actually installed you may see a high or low range value This feature 1s critical to know what values are respondi
3. 23 CJ TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 If Bit O of this value is high then the code is currently ACTIVE If low then it is inactive 1 1 2 20 1 2 AB LE _CLNT_Custom_H20il_US_1 3 08 Monico DSPLE MonicoView File Edit Wiew Link Help Dee X be x oo Communications p ox d r3 GenSet1_REAL Available Mappings GenSetl REAL 3 amp E Bl Monico DSP GenSeti REAL 4 rim cp GenSetl_REAL 5 Monico IDs 001 050 GenSet1_REAL 6 Monico IDs 051 100 m GenSeti REAL 7 Monico IDs 101 150 5m Block 4 Monico IDs 151 200 GenSeti REAL 8 CDL FaultSourcedo Monico IDs 201 250 GenSeti REAL 9 CDL FaultSourcedl Monico IDs 251 300 GenSetl_REAL 10 CDL FaultSource0z Monico IDs 301 350 GenSetl_REAL 11 CDL FaultSourced3 Monico IDs 351 400 GenSeti_REAL 12 CDL FaultSource04 Monico IDs 401 407 GenSeti REAL 13 CDL FaultCodeoo FaultSource GenSeti REAL 14 CDL FaultCode0i FaultCode GenSeti REAL 15 CDL FaultCode0 2 FaultSubcode GenSeti_REAL 16 CDL FaultCode03 FaultFlags GenSeti REAL 17 CDL FaultCode04 FaultCount GenSeti_REAL 18 CDL FaultSubcode00 FaultFirst GenSeti_REAL 19 CDL FaultSubcode0i FaultLast GenSeti REAL 20 CDL FaultSubcode02 GenSet1_REAL 21 CDL FaultSubcode03 GenSeti REAL 22 CDL FaultSubcode04 GenSeti_REAL 23 CDL FaultFlags00 GenSeti_REAL 24 CDL FaultFlags01 GenSet1_REAL 25 CDL FaultFlags02
4. INT x DINT x and REAL x representing Integers INT Double Integers DINT and Floating Point values REAL Each array will have multiple EL_EMENTS represented by x For example to represent Generator Set 1 parameter one might be GenSet1_INT 0 which would represent ELEMENT 0 of the INTEGER array for the DEVICE GenSet1 This tag would be mapped to a particular Raw value or Calculated value depending on the version In MonicoView this could be shown mapped as shown in figure E 1 below MAKE SURE YOU HAVE AT LEAST AS MANY ELEMENTS IN YOUR CONTROLLER TAG IN THE PLC AS WE HAVE MAPPED IF YOU HAVE TOO MANY IT IS OK HOWEVER IF YOU HAVE ONE LESS ELEMENT THAN MAPPED IN MONICOVIEW COMMUNICATIONS ERRORS WILL RESULT 44 MOTI SIMPLE SOLUTIONS POWERFUL MONITORING Tha E Monico DSP Programming Port RS 232 Comms Port RS 485 Comms Port DF1 Master EH StatusValues Block 1 Em RawValues Block 1 Ethernet 3 Protocol 1 AB Tag Names EH GenSeti Block 1 GenSeti1 INT 0 CDL7 REMOTE FAULT RESET GenSeti_INT 1 CDL10 COOLDOVVN DURATION GenSeti INT 2 CDL13 REM START STATUS GenSeti_INT 3 CDL15 ENG CONTROL SVv POS GenSeti_INT 4 CDL22 GEN PHASE SELECT GenSeti_INT 5 CDL23 REMOTE ESTOP GenSeti_INT 6 CDL24 COOL OVERIDE CONT GenSeti INT 7 CDL57 GEN ACV XFOR SP GenSeti INT 8 CDL58 GEN ACC FS SP GenSeti_INT 9 CDL59 GEN PH A PF LD LAG GenSeti_INT
5. Multistate 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 Modbus Manual Remarks Id Address ngine Control Switch Position 30015 0 Off reset 2 Start 3 Stop 4 Auto na hutdown Notify Relay Status 30016 O Relay is OFF 1 Relay is ON tart up Mode Status 30019 OzStarter is OFF 1 Starter is ON 2 Overcrank 3 Startup Successful 224 255 are Fault Identifiers Engine Prelube Status 30027 Starting at 0 Prelube OFF ON DISABLED OMPLETED 4 255 are Fault Identifiers 30 Remote Throttle Override Generator Set Only 30030 Normal throttle setting 1 Low idle setting 224 255 are Fault Identifiers 32 Low Idle Switch Position Switch is OFF 1 Switch is ON 224 255 are Fault Identifiers 29 CJ TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 59 enerator Phase A Power Factor Lead Lag Status 30059 O Current lags voltage 1 Current leads voltage 224 255 Fault Identifiers queen lags voltage 1 Current leads voltage 224 255 Fault Identifiers p m Tl m lags voltage 1 Current leads voltage 224 255 Fault Identifiers e i lags voltage 1 Current leads voltage 224 255 Fault Identifiers i e Eee low Engine Coolant Pump Pressure Status 30151 coolant pressure OK 1 coolant pressure too high 2 Too Low
6. 0 223 is Valid Range 224 255 are Fault Identifiers ydrax Oil Pressure Switch Status 30200 22 Open 23 Closed 65504 65535 are Fault Identifiers Emissions Feedback Mode 30202 394 Combustion Time Feedback 395 Exhaust Temperature Feedback 397 Calibration Feedback 398 No Feedback 65504 65535 are Fault Identifiers Multistate Read from modbus register as unsigned integer The value indicates different status conditions depending on the value being read See details below Monico PID Description Modbus Manual Remarks Id Address enerator Phase Select 30022 O Phase A B Volts A current 1 Phase B C Volts B current 2 Phase C A Volts C current enerator AC Voltage Full Scale and External PT 700v 1 150v 2 300 3 500 4 600 5 750 6 3k Setpoint 4 5k 8 5 25k 9 9k 10 15k 11 18k 12 30k starting at 0 5 100 150 200 300 400 600 800 1k 1 2k 1 5k 2k 2 5k 3k 4k enerator AC Voltage Full Scale Transformer Setpoint 700v 1 150v 2 300 3 500 4 600 5 750 6 3k 4 5k 8 5 25k 9 9k 10 15k 11 18k 12 30k enerator AC Current Full Scale Setpoint 30058 Starting at 0 5 100 150 200 300 400 600 800 1k 1 2k 1 5k 2k 2 5k 3k 4k Remote Generator Synchronizer Control GSP P only 30068 This can be written to 0 Off 1 Remote synchronization est 2 Automatic synchronization esting Synchronizing Synchronization system alarm or diag Remote synchronization testing passed Dead bus time delay Closing to dead bus Normal Stop In
7. Efl Host232 escena ce an Drop Number 1 Hl Block a dn Weeks Word Ordering ell Block 4 In Long Blocks Low Then High ll Block 5 RS 485 Comms Port Modbus RTU Slave 1n Real Blocks Low Then High Ef Host485 Ml Block 1 Port Settings aor Data Bits Eight H 0 Block 5 Hak Ethernet Stop Bits one z EX Protocol 1 Modbus TCP IP Slave E HostTCPIP Parity None d Block 2 ee c Block 3 Baud Rate 19600 Y E Block 1 l Block 2 Port Sharing H Block 3 S ft on na Share Port No Lr ror E Block 5 Protocol 2 Yi Clear Port Settings Restore Driver Defaults Close Figure 6 3 Serial Port Communications Settings To change any of the settings shown in Figure 6 3 highlight the value and enter the new setting and press enter to record the change If the value is in a drop down window just select the new settings Notice that you can set a Drop Number This allows you to use the RS 232 port with a multi drop network using RS 232 to RS 485 converters Enter the Device Address for the CDL Gateway in the case of Slave protocols in the Drop Number box and press ENTER If the port is setup as a Master Device then the target drop number will be entered 16 CJ Tra CNIC SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 The only difference with the RS 485 port is choosing whether you want 2 wire RS 485 or 4 wire RS 485 or RS 422 This screen i
8. IDs 001 050 Monico IDs 051 100 Monico IDs 101 150 Monico IDs 151 200 Monico IDs 201 250 Monico IDs 251 300 Monico IDs 301 350 Monico IDs 351 400 Monico IDs 401 407 FaultSource FaultCode FaultSubcode GenSetl REAL 23 CDL FaultFlags00 GenSeti_REAL 24 CDL FaultFlags 1 GenSeti_REAL 25 CDL FaultFlags02 GenSetl REAL 26 CDL FaultFlags03 GenSeti_REAL 27 CDL FaultFlags 4 GenSeti_REAL 28 CDL FaultCount00 GenSeti_REAL 29 CDL FaultCount01 GenSeti_REAL 30 CDL FaultCount0 GenSet1_REAL 31 CDL FaultCount03 GenSetl REAL 32 CDL FaultCount04 GenSeti_REAL 33 CDL FaultFirst00 m m X X4 M M XM mM M EX OM mM e N he IR FaultFlags FaultCount FaultFirst FaultLast MID Status Serial Number GenSetl REAL 34 CDL FaultFirst01 Not Mapped GenSeti REAL 35 CDL FaultFirst02 GenSeti REAL 36 CDL FaultFirst03 GenSet1_REAL 37 CDL FaultFirst04 GenSet1_REAL 38 CDL FaultLast00 GenSet1_REAL 39 CDL FaultLast01 GenSet1_REAL 40 CDL FaultLast02 X GenSeti_REAL 41 CDL FaultLast03 X GenSeti REAL 42 CDL FaultLast04 EJ Genset2 i OVER CAPS NUM 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 1s not required in the majority of applications Creating custom Fault Blocks is easily accomplished using MonicoView Pr
9. MMNXNEMXEMNENEXXEXXX GenSeti_REAL 26 CDL FaultFlags 3 GenSeti_REAL 27 CDL FaultFlags04 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 3 will result in detailed fault and event codes information for the most recent five fault codes as sorted by Last Occurrence If more than the last 25 codes are desired the list is easily expanded DA CJ TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING 1 1 2 20 1 2 AB LE CLNT Custom H20Oil US 1 3 08 Monico DSPLE MonicoView File Edit View Link Help Da EB X mo XIn s Communications Bs GenSeti_REAL 8 CDL FaultSource00 GenSetl REAL 9 CDL FaultSource0i GenSetl REAL 10 CDL FaultSource02 GenSet1 REAL 11 CDL FaultSource03 GenSeti_REAL 12 CDL FaultSource04 GenSeti_REAL 13 CDL FaultCode00 GenSetl REAL 14 CDL FaultCode01 GenSetl REAL 15 CDL FaultCode02 GenSeti_REAL 16 CDL FaultCodeU3 GenSeti_REAL 17 CDL FaultCode04 GenSeti_REAL 18 CDL FaultSubcode00 GenSeti_REAL 19 CDL FaultSubcode01 GenSeti REAL 20 CDL FaultSubcode02 GenSetl REAL 21 CDL FaultSubcode03 GenSetl REAL 22 CDL FaultSubcode04 Available Map s E E Monico DSP E Em COL HX Monico
10. Port 57 PPI v Enable Device Host232 E Block 1 m Device Settings Block 2 Drop Number o Block 3 i Block 4 Block 5 Delete This Device Add Gateway Block m Block 6 a RS 485 Comms Port S7 PPI HH Host485 E Block 1 B Block 2 B Block 3 n n mM 1 1 liil Block 4 Block 5 mW Block 6 H Ethernet 2 8 Protocol 1 S7 300 400 TCP IP Hl MasterTCPIP Protocol 2 Protocol 3 Protocol 4 El L Services gi orc Server H 4 CAT Link Option Card Si Close 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 Communications E E Monico DSP m Block Settings X Programming Port H RS 232 Comms Port SNP Master Start Address Amoo Z FE Host232 HOCK sees DO Gite m m Bod Block SI 106 Edi m Block 2 Direction Edit B Block3 B Block 4 B Block5 Block Control E R5 485 Comms Port SNP X Master Request ES FI Host485 Hm Block 1 Ecknowedger General Edite B Block2 B Block3 B Block4 View Block B Block5 l 4 Ethernet Protocol 1 DF1 Master FI HostTCPIP B Block 1 B Block2 B Block 3 B Block 4 M Block5 W Protocol 2 Protocol 3 X Protoc
11. X X X X X X x X X X pe X x X FX X x X FX X Figure 7 5 Number of Registers to Map Screen 21 SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 Appendix A CDL Gateway M Modbus Version Modbus Version Overview The Standard Modbus Version offers three host ports in slave mode They are e Modbus RTU Slave over RS 232 via the RJ 11 jack e Modbus RTU Slave over RS 485 2 wire or 4 wire via RJ 45 jack e Modbus TCP IP Slave over Ethernet via RJ 45 jack Other Modbus versions are available upon request such as a Modbus Master version One such scenario would be if you had several Modbus RTU Slave devices in the field and want to aggregate them into a single Modbus Data Map In this case we can setup the RS 485 to be a Modbus Master to poll the slave devices and map all the registers to the RS 232 or Ethernet port which would be setup as a Modbus Slave The CDL Gateway can also mix Modbus with other protocols such as BACnet and data maps for most of the popular PLC manufacturers One popular scenario is to use the CDL Gateway as a Modbus master to poll several slave devices on RS 485 bring in the engine data and combine all parameters into a single data map that is compatible with an Allen Bradley GE Fanuc or Siemens PLC Contact the factory to discuss your specific application Modbus Address Description The CDL Gateway M Modbus Version has a very simple pre assigned address syst
12. 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 Listed are some EMI guidelines for a successful installation in an industrial environment 1 To reduce the chance of noise spikes entering the unit via the power lines connections should be made to a clean source Connecting to circuits that also power loads such as contactors relays motors solenoids etc should be avoided 2 The unit should be mounted in a metal enclosure which is properly connected to protective earth 3 Use shielded screened cables for all Signal and Control inputs The shield screen pigtail connection should be made as short as possible The connection point for the shield depends somewhat upon the application Listed below are the recommended methods of connecting the shield in order of their effectiveness a Connect the shield to earth ground protective earth at one end where the unit is mounted b Connect the shield to earth ground at both ends of the cable usually when the noise source frequency is over MHz c Connect the shield to common of the Data Station and leave the other end of the shield unconnected and insulated from earth ground 4 Never run Signal or Control cables in the same conduit or ra
13. 10 CDL60 GEN FH B PF LD LAG GenSeti_INT 11 CDL61 GEN FH C PF LD LAG GenSeti_INT 12 CDL62 GEN AVE PF LD LAG1 GenSeti_INT 13 CDL63 REM START INITIATE GenSeti INT 14 CDL71 ENGINE RPM INT GenSeti INT 15 CDL72 GEN RING GEAR SP GenSeti_INT 16 CDL73 ENG COOL TEMP F GenSeti INT 17 CDL76 GENSET HOURS GenSeti INT 18 CDL79 RT EXH TEMP F GenSeti INT 19 CDL8O0 LT EXH TEMP F GenSeti_INT 20 CDL81 GEN RMSV A TO B GenSeti_INT 21 CDL8S2 GEN RMSV B TO C GenSeti INT 22 CDL83 GEN RMSV C TO A GenSeti_INT 23 CDL84 GEN RMSV A TO N GenSeti_INT 24 CDL85 GEN RMSV B TO N GenSeti INT 25 CDL86 GEN RMSV C TO N GenSeti INT 26 CDL87 GEN RMSC PH A GenSeti INT 27 CDL88 GEN RMSC PH B GenSeti_INT 28 CDL89 GEN RMSC PH C GenSeti INT 29 CDL90 GSC RELAY STATUS GenSeti INT 30 CDL91 GSC RELAY CONTROL GenSeti_INT 31 CDL93 GEN ALARM STATUS Figure E 1 Parameter Mapping KNXXXXNXXXNXXXXNXXXXXXXNXXXNXXXNXXXXXX El Monico DSP Programming Port X RS 232 Comms Port Ud RS 485 Comms Port DF1 Master Si Em StatusValues lil Block i RawValues Block 1 Ethernet Er Protocol 1 AB Tag Names Emm GensSetl El m Block 1 m Block 2 aa Te E m Block 3 GenSeti REAL O0 CDL263 SYS BATT VOLTS GenSeti_REAL 2 CDL287 GEM FREQUENCY GenSeti REAL 4 CDL291 GEM PH A PF GenSeti_REAL 5 CDL2902 GEM FH B PF GenSeti_REAL 6 CDL293_ GEN FH C PF GenSeti REAL 7 CDL294 GEN AVE
14. 11 Jack GCBLXXxxx Figure 4 2 RS 232 Connections Host Connections RS 485 RS 422 via RJ 45 Jack UBL xxxxxx Figure 4 3 RS 485 RS 422 Connections 10 SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 RS422 485 4 WIRE RS485 2 WIRE CONNECTIONS CONNECTIONS TxEN OC TxEN OC GND 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 GREEN AMBER LED YELLOW LED standard Ethernet cable p _ Figure 4 4 Ethernet Connections ETHERNET COMMUNICATIONS Ethernet communications can be established at either 10 BASE T or 100 BASE TX The Gateway s RJ45 jack Figure 4 4 is wired as a NIC Network Interface Card For example when wiring to a hub or switch use a straight through cable but when connecting to another NIC use a crossover cable Default IP Address is 192 168 1 10 a i ee SIMPLE SOLUTIONS POWERFUL MONITORING i 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
15. 62 Bits 2 1 0 None 1 Level 1 Warning 2 Level2 Warning Level 3 Warning Bit 3 amp 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 Bits O No active diag 1 At least 1 active diag eneral Alarm Output Status Override Marine Only 30071 This can be written to Bit 8 1 Override 0 Normal Bit 1 Output is OFF 1 Output is ON L ngine Status 30102 Bit 4 1 Fuel injection disabled 0 No injection disabled it5 1 E stop shutdown 0 No E stop shutdown Bit 1 No Engine Speed 0 Engine Speed SC Relay Status 30119 Organized by bit pairs where for each pair 0 Off de energized 1 On energized 3 Relay not installed Bits 6 e Cra Terminate Relay Bits 8 7 Starter Motor Relay its 10 9 Genset Fault Relay Bits 12 1 Run Relay Bits 14 13 Program Spare Relay Bits 16 15 Electronic Governor SC Relay Control 30120 i it pai elay Bits 8 7 Starter Motor Relay Bits 10 9 Genset Fault elay Bits 12 11 Run Relay Bits 14 13 Program Spare elay Bits 16 15 Electronic Governor Relay 30124 Organized by bit pairs where for each pair 0 Alarm Off 1 Alarm On 3 Not Available Bits 2 1 High Coolant Temp its 4 3 Low Coolant Temp Bits 6 5 Low Oil Psi Bits 8 7 Eng Control Switch not in Auto or Manual Bits 10 9 High Oil Temp Bits 12 11 Eng Control Alarm Bits 14 13 Not used Bits 16 15 Undefined SC Shutdown Status 30125 i it pai ir 0 its 8 Spare Fault Bit
16. Bit 6 not used Bit7 0 No eneral Alarm Output Status Override Marine Only 30065 This can be written to Bit 8 1 Override 0 Normal Bit 1 Output is OFF 1 Output is ON Engine Status 30077 it 4 1 Fuel injection disabled 0 No injection disabled it5 1 E stop shutdown 0 No E stop shutdown Bit 1 1 No Engine Speed 0 Engine Speed SC Relay Status 30090 Organized by bit pairs where for each pair 0 Off de energized 1 On energized 3 Relay not installed Bits 2 1 Air Shutoff Relay Bits 4 3 Fuel Control Relay Bits 6 5 Crank Terminate Relay Bits 8 7 Starter Motor Relay N ON N 65 7 7 its 10 9 Genset Fault Relay Bits 12 11 Run Relay Bits 14 13 Program Spare Relay Bits 16 15 Electronic Govenor SC Relay Control 30091 elay Bits 12 11 Run Relay Bits 14 13 Program Spare elay Bits 16 15 Electronic Govenor Relay SC Alarm Status 30093 Organized by bit pairs where for each pair 0 Alarm Off 1 Alarm On 3 Not Available Bits 2 1 High Coolant Temp its 4 3 Low Coolant Temp Bits 6 5 Low Oil Psi Bits 8 7 Eng Control Switch not in Auto or Manual Bits 10 9 High Oil Temp Bits 12 11 Eng Control Alarm Bits 14 13 Not used Bits 16 15 Undefined Oo 3 5j TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING Monico PID Description Modbus Manual Remarks Id Address SC Shutdown Status 30094 Organized by bit pairs where for each pair 0 Shutdown Inactive 1 Shutdown Active 3 Not Available Bit
17. CDL Gateway M Version 1 05 Installation and Operation Guide Tht SIMPLE SOLUTIONS POWERFUL MONITORING MONICO INC 3403 Chapel Square Spring Texas 77388 Tel 281 350 8751 sales MONICOINC com www MONICOINC com SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 Table of Contents MAMET ONC E EEEE 3 Secon D POWEP Supl y eea RR RR ARIE 4 Secon 2 Hardware TA sfalanionc3ssiicii iraniane in EE EEE N TATA 8 Secoli S PU EU See E E T UM 9 Section 4 CDL Gateway M Host COffeCcLlOTIS osicoscu siue re aee d used rue aua go eau a iraniana 9 Section Oe i Bie dole venido c pantssagre 12 Section 6 MonicoView Programmer and User Interface essere eene 13 Seccion 7S DiasnosHuc amd Evon 6 OUES asses uestis or unten eye Tem rrr tent DOO anne ener de ONU bI nt UNE ner ewer enter rt 22 Appendix A CDL Gateway M Modbus Version nnn nn nnne nennen sss se sns rrr nnne nennen 28 Modbus Register Conversion Details 29 Appendix B CDL Gateway CCM Translator Modbus Version nennen 36 Modbus Register Conversion Details i 36 Appendix C Modbus Viewer Program i 43 Appendix D GE Fanuc Version Notes ccccisecedscanvanasinnnnasewasncenneanducnsoasnaiennsnndaascecnkanawastinnepussacthn
18. D OMPLETED 4 255 are Fault Identifiers 32 Remote Throttle Override Generator Set Only 30034 Normal throttle setting 1 Low idle setting 224 255 are Fault Identifiers 34 Low Idle Switch Position 30036 Switch is OFF 1 Switch is ON 224 255 are Fault Identifiers pe oo lags voltage 1 Current leads voltage 224 255 Fault Identifiers Im lags voltage 1 Current leads voltage 224 255 Fault Identifiers pec ao Co lags voltage 1 Current leads voltage 224 255 Fault Identifiers pau Eni enin lags voltage 1 Current leads voltage 224 255 Fault Identifiers ii EE low Engine Coolant Pump Pressure Status 30290 O coolant pressure OK 1 coolant pressure too high 2 Too Low 0 223 is Valid Range 224 255 are Fault Identifiers ydrax Oil Pressure Switch Status 30362 22 Open 23 Closed 65504 65535 are Fault Identifiers Emissions Feedback Mode 30364 B94 Combustion Time Feedback 395 Exhaust Temperature Feedback 397 Calibration Feedback 398 No Feedback 65504 65535 are Fault Identifiers Multistate Read from Modbus register as unsigned integer The value indicates different status conditions depending on the Caterpillar value being read See details below Monico PID Description Modbus Manual Remarks Id Address 37 CJ TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING Monico PID Description Modbus Manual Remarks Address 24 enerator Phase Select 30026 O Ph
19. E 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 In this version like all the PLC versions the gains have been applied and the units have been converted to US unit Metric Unit versions are available upon request This application of the gain and units conversion saves the programmer a great deal of time because it offers the values without needed math operations This section is not meant to be a user guide for the PLC just additional information useful for use of the CDL Gateway with the GE Fanuc Series 90 and Versamax Modular If you have other GE Fanuc models please consult the factory for custom versions available Address Block Descriptions All values are written to Analog Input Registers This block of registers 1s used because they are rarely used in the higher address ranges used by the Gateway By starting at AI1001 we are attempting to prevent conflicts with existing code already written in the PLC In GE Fanuc there is not real difference in the Analog Input Registers and the Data Registers However the Data Registers are used for all timers and counters and in some instances are used extensively Other Address Block ranges are available upon request Parameter Status Values The four blocks for viewing which Parameters are available on your specific installation are setup in Registers AI2001 AI2xxx It is not norma
20. High aftercooler coolant temperature bit 14 High crankcase pressure bit 15 Fuel filter plugged bit 16 Oil filter plugged bit 17 Not used bit 18 Not used bit 19 Low coolant level bit 20 Alternator NOT charging bit 21 Low fuel level bit 22 High transmission oil pressure bit 23 Low transmission oil pressure bit 24 High transmission oil temperature bit 25 32 Not used 240 hutdown Status 30240 Each of the first 24 bits represents Shutdown status 0 Engine Shutdown is NOT ACTIVE Engine Shutdown is ACTIVE bit 1 High exhaust temperature bit 2 High altitude atmospheric pressure bit 3 Air filter plugged bit 4 Engine overspeed bit 5 Low engine coolant temperature bit 6 High engine coolant temperature bit 7 Low engine oil pressure bit 8 High system voltage bit 9 High engine inlet air temperature bit 10 High engine oil temperature bit 11 High hydraulic oil temperature bit 12 No coolant flow bit 13 High aftercooler coolant temperature bit 14 High crankcase pressure bit 15 Fuel filter plugged bit 16 Oil filter plugged bit 17 Not used bit 18 Not used bit 19 Low coolant level bit 20 Alternator NOT charging bit 21 Low fuel level bit 22 High transmission oil pressure bit 23 Low transmission oil pressure bit 24 High transmission oil temperature bit 25 32 Not used Engine Derate Status 30241 Each of the first 24 bits represents Eng Derate status 0 Engine Derate i
21. In most cases the Gain and Unit Conversions For US units are already done which saves substantial programming time in the PLC Please refer to the latest Combined Data Map available for download at www monicoinc com downloads One limitation to be remembered 1s that Allen Bradley does not allow more than 256 elements under each section So if you choose N107 0000 as the starting address then N107 0255 is the last valid element Also the register ID 07 as in NO7 0000 is reserved for 16 bit Integers only The register ID 08 1s reserved for the first Floating Point group as in F08 0000 Higher numbers above these two values can be used for any data type Communications with MicroLogix 1100 over Ethernet must use the DF Master over PCCC IP option Appendix F Siemens Notes In versions programmed for Siemens S5 amp S7 the Gateway normally uses the Data Block registers We normally begin with DB1000 0000 so we do not have conflicts with existing programs However any Data Blocks can be used In the PLC program you must create the Data Blocks and define the names and Data Types When Using TCP IP you must set the IP address of the Gateway and the IP address and Slot Number of the PLC PROCESSOR The IP address of the Gateway is set after highlighting the ETHERNET port under the COMMUNICATIONS section in MonicoView The target PLC address is set after highlighting the PLC Device in the communications section The Gateway acts as
22. ONS POWERFUL MONITORING 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 Hex to Integer For signed values Value should be read from the modbus registers as a signed integer After being read multiply by the gain and add the offset For unsigned values Value should be read from the modbus registers as an unsigned integer After being read multiply by the gain and add the offset Engine Type Code as 3 Digit Integer Format is XY Y where X is the engine family and YY is the number of cylinders Negative A ctive Positive Inactive A value of 0 indicates that the status is inactive disabled or off A value of 1 indicates that the status 1s active enabled or on Diagnostic Codes 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 1s 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 1s active enabled or on
23. PF x x LM X X x x x Fine E 2 Data Mapping Example GenSeti DINT 0 CDL242 SPARE OUTPT LONG GenSeti_DINT 1 CDL243 GEN TOT REAL LG GenSeti DINT 2 CDLZ44 REL MOD REL LONG GenSeti DINT 3 CDL245 PH A REAL P LONG GenSeti DINT 4 CDL246 PH B REAL P LONG GenSeti DINT 5 CDL247 PH C REAL P LONG GenSeti DINT 6 CDL248 PH A REACT P LONG GenSeti DINT 7 CDL249 PH B REACT P LONG GenSeti DINT 8 CDL250 PH C REACT PF LONG GenSeti DINT 9 CDL251 TOT REACT P LONG GenSeti_DINT 10 CDL252 PH A APPAR P LONG GenSeti DINT 11 CDL253 PH B APPAR P LONG GenSeti DINT 12 CDL254 PH C APPAR P LONG GenSeti_DINT 13 CDL255 TOT APPAR P LONG GenSeti DINT 14 CDL256 GEN TOT KWH LONG GenSeti DINT 15 CDL257 TOT KVAR HR LONG GenSeti_DINT 16 CDL258 GEM SHUTDN LONG GenSeti DINT 17 CDL259 GEM ALARM LONG GenSeti REAL 1 CDL271 EMG OIL PRESS PSI GenSeti_REAL 3 CDL290_GEN_POW_PERCNT v1 05 6 26 09 An example of the overall mapping using the other two data types 1s shown in E 2 below _ 45 Tra SIMPLE SOLUTIONS POWERFUL MONITORING 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 DFI Master and pushes the engine data into the mapped data registers in the PLC but it can read data from the PLC as well
24. POWERFUL MONITORING v1 05 6 26 09 Communications H Monico DSP gu Programming Port Modbus RTU Slave pH PIDSTATUS EM Blocki i RS 232 Comms Port Modbus RTU Slave EL Host232 mW Block 1 m Block 2 m Block 3 amp m Block4 ell Block 5 E RS 485 Comms Port Modbus RTU Slave ll Host485 uc Cu kd Enable Full Duplex Block 2 v Enable High Speed Block 3 Block 4 ll Block 5 H Ethernet Protocol 1 Modbus TCP IP Slave Ef HostTCPIP H E Block 1 tm Block 2 Block 3 n Block 4 E Block 5 Protocol 2 1 Protocol 3 Protocol 4 S Services ju Close gt il iH Maximum Segment Size For Send 1280 El dl FH Part Sumber H 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 By disabling unused ports you will maximize the performance of the Gateway 18 CJ TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING Communications El Monico DSP Device Settings Programming Port zl RS 232 Comms
25. a Master in this application and pushes the data into the PLC Data Blocks When we act as a Master over Serial Networks the Gateway needs to be the only Master on the network Therefore when using PPI or MPI communications you cannot use the Gateway AND a Siemens HMI because both devices will be a Master and this will not work In this case your options are to install a CP343 1 Ethernet module use the Gateway HMI version to replace the Siemens HMI or upgrade the PLC processor to a version with onboard Ethernet 46
26. ad bus 330 Normal Stop Input Status 113 Run 174 Stop 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 Modbus Manual Remarks Id Address Oxygen Sensor Status 30006 Bits set to 1 indicate Status 8 start cal 7 cal in progress 6 sensor on 5 command sensor on Ignition Timing Calibration 30008 Bits set to 1 indicate Status 8 cal good else cal bad 7 enable cal else disable cal ee O idle 1 rated Bit7 O off grid 1 on grid Bit6 5 00 running 01 coasting 10 shutdown 11 not used Vee 606 O genset l industrial Bit6 O isochronous governor 1 droop governor 48 Auxiliary Status 30050 Mode Control Switch Bit8 7 11 start 10 auto 01 stop 00 off reset E Stop Bit 6 l stop O run Driven Equipment Bit5 1 Ready 0 Not Ready Prelube Slave elay Bit4 IZON 22OFF Prelube Relay Bit3 12ON 2 OFF Prelube Switch Bit2 1 Not Ready 0 Ready Initiate Contact Bitl 1 Stop 0 Run 55 EIS Special Test Status Inactive Tests should only be done on site bit 8 1 Enable special test O2disable Bit7 O2proceed to test B Bit5 1 test passed Non zero of tests failed 38 5 TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 inn PID er pro Manual Remarks eee ls Diagnostic Status Summary 300
27. ase A B Volts A current 1 Phase B C Volts B current 2 Phase C A Volts C current 7 enerator AC Voltage Full Scale and External PT 30029 0 700v 1 150v 22300 32500 42600 52750 6 3k v1 05 6 26 09 p EG 2 Setpoint 4 5k 8 5 25k 9 9k 10 15k 11 18k 12 30k enerator AC Current Full Scale Setpoint Read 30030 starting at 0 5 100 150 200 300 400 600 800 1k 1 2k 1 5k 2k 2 5k 3k 4k ECM in Control Marine Only 30035 enerator AC Voltage Full Scale Transformer Setpoint 30063 0 700v 1 150v 22300 32500 42600 52750 6 3k NO ioe ON ON m 4 5k 8 5 25k 9 9k 10 15k 11 18k 12 30k enerator AC Current Full Scale Setpoint 30064 Starting at 0 5 100 150 200 300 400 600 800 1k 1 2k 1 5k 2k 2 5k 3k 4k 72 Remote Generator Synchronizer Control GSP P only 30074 This can be written to 0 Off 1 Remote synchronization est 2 Automatic synchronization emote Synchronization Control Readiness GSP P 30076 DzNot installed 1 ready for remote command only 2 Synchronizing switch not in auto 3 Engine control switch QI Go AJ not in auto 4 Engine was not started remotely 5 Engine not running enerator Synchronizer Control Status GSP P only 30077 Starting at 0 Not installed Inactive Semiautomatic paralleling Permissive paralleling Remote synchronization 4 PS esting Synchronizing Synchronization system alarm or diag Remote synchronization testing passed Dead bus time delay Closing to de
28. ay MAKE SURE YOU HAVE THIS MANUAL AND THE MODBUS DATA MAP WHEN GOING INTO THE FIELD TO INSTALL THE GATEWAY The same groups of addresses are assigned to all of the Host Ports Therefore you can poll the same registers from either the RS 485 RJ 45 port the RS 232 RJ 11 Port or the Ethernet RJ 45 port The purpose of these versions is to simulate the same addresses as our Monico CCM Translator but these versions need to be specifically requested We also offer versions that utilize other protocols such as BACnet instead of Modbus Other versions act as remote devices for Allen Bradley Ethernet IP or GE Fanuc PLC s etc If you are being forced to convert Modbus into another format or protocol please give Monico Technical Support a call We may be able to save you time and money Modbus Register Conversion Details All values are transmitted 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 Hex to Integer For signed values Value should be read from the Modbus registers as a signed integer After being read multiply by the gain and add the offset For unsigned values Value should be read from the Modbus registers as an unsigned
29. ceway with AC power lines conductors feeding motors solenoids SCR controls and heaters etc The cables should be run through metal conduit that is properly grounded This is especially useful in applications where cable runs are long and portable two way radios are used in close proximity or if the installation is near a commercial radio transmitter Also Signal or Control cables within an enclosure should be routed as far away as possible from contactors control relays transformers and other noisy components 5 Long cable runs are more susceptible to EMI pickup than short cable runs Therefore keep cable runs as short as possible 6 In extremely high EMI environments the use of external EMI suppression devices 1s effective The following EMI suppression devices or equivalent are recommended Ferrite Suppression Cores for signal and control cables Fair Rite part number 0443167251 RLC part number FCOR0000 TDK part number ZCAT3035 1330A Steward part number 28B2029 0A0 Line Filters for input power cables Schaffner part number FN610 1 07 RLC part number LFIL0000 Schaffner part number FN670 1 8 07 Corcom part number 1 VR3 SPECIFICATIONS 1 POWER 24 VDC 10 200 mA min without expansion card Amp maximum with expansion card fitted Must use Class 2 or SELV rated power supply 2 COMMUNICATIONS USB PG Port Adheres to USB specification 1 1 Device only using Type B connection Serial Ports Format and Baud Rates fo
30. em 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 Since this is primarily a monitoring device our default version uses Input Registers only The Modbus Data Map is available on the Downloads page of the Monico Inc web site www monicoinc com The data map provides extensive details needed for successful installation and operation of the Gateway MAKE SURE YOU HAVE THIS MANUAL AND THE MODBUS DATA MAP WHEN GOING INTO THE FIELD TO INSTALL THE GATEWAY The same groups of addresses are assigned to all of the Host Ports Therefore you can poll the same registers from either the RS 485 RJ 45 port the RS 232 RJ 11 Port or the Ethernet RJ 45 port IT IS HIGHLY RECOMMENDED TO DISABLE ANY UNUSED PORTS TO OPTIMIZE GATEWAY PERFORMANCE There are other versions of this device that will simulate the same addresses as our Monico CCM Translator but that version needs to be specifically requested We also offer versions that utilize other protocols such as BACnet instead of Modbus Other versions act as remote devices for Allen Bradley Ethernet IP or GE Fanuc PLC s etc If you are being forced to convert Modbus into another format or protocol please give Monico Technical Support a call We may be able to save you time and money 28 CJ TRE Cor iit SIMPLE SOLUTI
31. enSet1_REAL 75 GenSeti_REAL 76 GenSet1_REAL 77 Available Mappings i Monico DSP COL X Monico IDs 001 050 Select CAT Data Link Item PID Data Value PID Status Word Figure 7 4 Fault Block Creation Example 26 CJ TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING 1 1 2 20 1 2 AB LE CLNT_Custom_H20il_US_1 3 08 Monico DSPLE MonicoView File Edit View Link Help Deal s E amp x D s Communications m Block 5 GenSeti_REAL 43 CDL FaultSource00 GenSeti REAL 44 OE GenSeti_REAL 45 i X Monico IDs 001 050 GenSeti REAL 46 i i X Monico IDs 051 100 GenSeti REAL 47 X Monico IDs 101 150 GenSeti REAL 48 X Monico IDs 151 200 GenSeti REAL 49 i X Monico IDs 201 250 GenSeti REAL 50 i i X Monico IDs 251 300 GenSeti REAL 51 i t X Monico IDs 301 350 GenSeti REAL 52 s 351 400 GenSeti REAL 53 Create Mapping GenSeti REAL 54 GenSeti REAL 55 GenSeti REAL 56 GenSeti REAL 57 GenSeti REAL 58 GenSeti REAL 59 GenSeti REAL 60 GenSeti REAL 61 GenSeti REAL 62 GenSeti REAL 63 GenSeti REAL 64 GenSeti REAL 65 GenSeti REAL 66 GenSeti REAL 67 GenSeti REAL 68 GenSeti REAL 69 GenSeti REAL 70 GenSeti REAL 71 GenSetl REAL 72 GenSeti REAL 73 GenSeti REAL 74 GenSeti REAL 75 GenSeti REAL 76 GenSeti REAL 77 X FSK X X X x X X X X X X x FSX E M
32. engine oil temperature bit 11 High hydraulic oil temperature bit 12 No coolant flow bit 13 High aftercooler coolant temperature bit 14 High crankcase pressure bit 15 Fuel filter plugged bit 16 Oil filter plugged bit 17 Not used bit 18 Not used bit 19 Low coolant level bit 20 Alternator NOT charging bit 21 Low fuel level bit 22 High transmission oil pressure bit 23 Low transmission oil pressure bit 24 High transmission oil temperature bit 25 32 Not used 194 hutdown Status Each of the first 24 bits represents Shutdown status 0 Engine Shutdown is NOT ACTIVE 1 Engine Shutdown is ACTIVE 40 CJ TRE n i SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 Monico PID Description Modbus Manual Remarks Id Address bit 1 High exhaust temperature bit 2 High altitude atmospheric pressure bit 3 Air filter plugged bit 4 Engine overspeed bit 5 Low engine coolant temperature bit 6 High engine coolant temperature bit 7 Low engine oil pressure bit 8 High system voltage bit 9 High engine inlet air temperature bit 10 High engine oil temperature bit 11 High hydraulic oil temperature bit 12 No coolant flow bit 13 High aftercooler coolant temperature bit 14 High crankcase pressure bit 15 Fuel filter plugged bit 16 Oil filter plugged bit 17 Not used bit 18 Not used bit 19 Low coolant level bit 20 Alternator NOT charging bit 21 Low
33. esdiveceapaeasacanivancionns 43 Appendix E Allen Bradley Version Notes ccccccccccccccscccesssssseseeeeecccceceeceecessaaaeessssseeseseceeceesseeaeeasssseeeeseeeess 44 Appendix F Siemens Notes oue ders ironia orione ina Cuore Run 46 SIMPLE SOLUTIONS POWERFUL MONITORING 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 amp ADEM III ECM s EIS and AFR controls The CDL Gateway is NOT an engine controller and is only used for monitoring engine and generator parameters Like our previous products it will automatically interrogate the CDL and determine which controllers are present on the network It will then poll all possible parameters to determine which parameters are present on that particular installation All values are in pre assigned registers to minimize setup time It is our intention to always provide a product that requires little or no setup to function in a wide variety of applications However any of our programs are modifiable using MonicoView software which is available for download on our website at wwW monicoinc com Make sure to check the web
34. fuel level bit 22 High transmission oil pressure bit 23 Low transmission oil pressure bit 24 High transmission oil temperature bit 25 32 Not used 195 Engine Derate Status 30207 Each of the first 24 bits represents Eng Derate status 0 Engine Derate is NOT ACTIVE Engine Derate is ACTIVE bit 1 High exhaust temperature bit 2 High altitude atmospheric pressure bit 3 Air filter plugged bit 4 2 Engine overspeed bit 5 Low engine coolant temperature bit 6 High engine coolant temperature bit 7 2 Low engine oil pressure bit 8 High system voltage bit 9 High engine inlet air temperature bit 10 High engine oil temperature bit 11 High hydraulic oil temperature bit 12 No coolant flow bit 13 High aftercooler coolant temperature bit 14 High crankcase pressure bit 15 Fuel filter plugged bit 16 Oil filter plugged bit 17 Not used bit 18 Not used bit 19 Low coolant level bit 20 Alternator NOT charging bit 21 Low fuel level bit 22 High transmission oil pressure bit 23 Low transmission oil pressure bit 24 High transmission oil temperature bit 25 32 Not used ndefined 0 OFF 1 ON 16 Output Fault 17 Output not available elay Driver Module Relay State 30213 writable For each group of bits 00 OFF DE ENERGIZED 01 ON ENERGIZED 10 Output fault 11 Output not available Don t change state bits 1 2 Undefined future use bits 3 4 Undefined future use bits 5 6 Undefined
35. future use bits 7 8 Undefined future use pare Outputs GSC only 30209 writable Bits 26 25 Spare Output All other bit pairs are _4 CJ TRE n i SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 inn PID MEE Modbus Manual Remarks se bits 9 10 Output 9 bits 11 12 Undefined future use bits 13 14 Undefined future use bits 15 16 Undefined future use bits 17 18 Output 5 bits 19 20 Output 6 bits 21 22 Output 7 bits 23 24 Output 8 bits 25 26 Output 1 bits 27 28 Output 2 bits 29 30 Output 3 bits 31 32 Output 4 enerator Shutdown Status GSC only 30241 For each group of bits 00 Shutdown inactive 01 hutdown active 10 Undefined 11 Not available or not installed bits 1 2 Underfrequency bits 3 4 Overfrequency bits 5 6 Undervoltage bits 7 8 Overvoltage bits 9 10 Generator Frequency Sensing Fault bits 11 12 Generator Total Overcurrent bits 13 14 Single Phase Overcurrent bits 15 16 Reverse Power bits 17 18 Undefined future use bits 19 20 Undefined future use bits 21 22 Undefined future use bits 23 24 Generator Freq Inconsistent w Eng Speed bits 25 26 Undefined future use bits 27 28 Undefined future use bits 29 30 Undefined future use bits 31 32 Undefined future use enerator Alarm Status GSC only 30243 For each group of bits 00 Alarm inactive 01 Alarm active 10 Undefined 11 Not available or not ins
36. here to look for the appropriate files 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 INSTEAD choose Install From List or Specific Location click NEXT and use the Browse button to select the following location C Program Files Monico Monicoview Device Click Next and follow the instructions below to finish the process From this point on you can use the Automatic Install option which is much simpler 13 5j TRE CNIC SIMPLE SOLUTIONS POWERFUL MONITORING 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 Found New Hardware Wizard This wizard helps you install software for G3 Loader If your hardware came with an installation CD or sup floppy disk insert it now What do you wantthe wizard to do 8 Install the software automatically Recommended C Install from a list or specific location Advanced Click Next to continue Figu
37. integer After being read multiply by the gain and add the offset Engine Type Code as 3 Digit Integers Format is XY Y where X is the engine family and YY is the number of cylinders Negative A ctive Positive Inactive A value of 0 indicates that the status is inactive disabled or off A value of 1 indicates that the status 1s active enabled or on 36 5 TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING 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 1s 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 1s active enabled or on Multistate 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 Modbus Manual Remarks Id Address EM ngine Control Switch Position 30019 0 Off reset 2 Start 3 Stop 4 Auto hutdown Notify Relay Status 30020 0 Relay is OFF 1 Relay is ON tart up Mode Status 30023 Starter is OFF 1 Starter is ON 2 Overcrank 3 Startup Successful 224 255 are Fault Identifiers Engine Prelube Status 30031 Starting at 0 Prelube OFF ON DISABLE
38. ith a meter If you must use an external power supply it is very important that the power supply is mounted correctly 1f the unit 1s 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 8 m of cable between the supply and the Gateway Ideally the shortest length possible should be used The wire used to connect the Gateway s power supply should be at least 22 gage wire If a longer cable run is used a heavier gage wire should be used The routing of the cable should be kept away from large contactors inverters and other devices which may generate significant electrical noise A power supply with a Class 2 or SELV rating is to be used A Class 2 or SELV power supply provides isolation to accessible circuits from hazardous voltage levels generated by a mains power supply due to single faults SELV is an acronym for safety extra low voltage Safety extra low voltage circuits shall exhibit voltages safe to touch both under normal operating conditions and after a single fault such as a breakdown of a layer of basic insulation or after the failure of a single component has occurred once SIMPLE SOLUTIONS POWERFUL MONITORING 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
39. its 11 12 Undefined future use bits 13 14 Undefined future use bits 15 16 Undefined future use bits 17 18 Output 5 bits 19 20 Output 6 bits 21 22 Output 7 bits 23 24 Output 8 bits 25 26 Output 1 bits 27 28 Output 2 bits 29 30 Output 3 bits 31 32 Output 4 enerator Shutdown Status GSC only bits 1 2 Underfrequency bits 3 4 Overfrequency bits 5 6 Undervoltage bits 7 8 Overvoltage bits 9 10 Generator Frequency Sensing Fault bits 11 12 Generator Total Overcurrent bits 13 14 Single Phase Overcurrent bits 15 16 Reverse Power bits 17 18 Undefined future use bits 19 20 Undefined future use bits 21 22 Undefined future use bits 23 24 Generator Freq Inconsistent w Eng Speed bits 25 26 Undefined future use bits 27 28 Undefined future use bits 29 30 Undefined future use bits 31 32 Undefined future use enerator Alarm Status GSC only 30259 For each group of bits 00 Alarm inactive 01 Alarm Bd 5j TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING Monico PID Description Modbus Manual Remarks Id Address active 10 Undefined 11 Not available or not installed bits 1 2 Underfrequency bits 3 4 Overfrequency bits 5 6 Undervoltage bits 7 8 Overvoltage bits 9 10 Generator Frequency Sensing Fault bits 11 12 Generator Total Overcurrent bits 13 14 Single Phase Overcurrent bits 15 16 Reverse Power bits 17 18 Undefined fut
40. ive NonZero Active A value of 0 indicates that the status is inactive disabled or off A value of 1 indicates that the status 1s active enabled or on Hex to Long Integer The value is contained in 2 consecutive Modbus registers For example if the first value is at address 40001 the value at 40002 will also need to be read Read each register as an unsigned integer Take the first value and multiply by 65536 Then add the second value Multiply the result by the gain and add the offset Long Multiple Status Bits The value is contained in 2 consecutive Modbus registers For example if the first value is at address 30001 the value at 30002 will also need to be read Read each register as an unsigned integer Take the first value and multiply by 65536 Then add the second value The result 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 Modbus Manual Remarks Id Address 193 arning Status 30203 Each of the first 24 bits represents warning status 0 Warning is NOT ACTIVE Warning is ACTIVE bit 1 High exhaust temperature bit 2 High altitude atmospheric pressure bit 3 Air filter plugged bit 4 Engine overspeed bit 5 Low engine coolant temperature bit 6 High engine coolant temperature bit 7 Low engine oil pressure bit 8 High system voltage bit 9 High engine inlet air temperature bit 10 High
41. lly recommended that you continually monitor these values but you can if so desired After satisfactory installation it 1s recommended that you disable this device to optimize performance You can always enable the device in the future for troubleshooting purposes 43 SIMPLE SOLUTIONS POWERFUL MONITORING 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 Appendix E Allen Bradley Version Notes Controller Tag Versions The controller tag version is intended for use with ControlLogix and CompactLogix Allen Bradley models The controller tags can be created in the PLC exported via CSV file and imported into MonicoView or as in the case with the Standard Factory versions simply create our standard Controller Tags listed in the Combine Data Map in the PLC program and the parameters will be pushed to the PLC under these tag names Address Block Descriptions Since the ControlLogix series of PLC does not use the same addressing system as the PLC 5 and SLC we need to use the Native Data Tag system We must create one TAG ARRAY for each type of data So we use three tag arrays labeled
42. munication is only a few seconds using CDL Monitor 2 0 instead of up to 10 minutes using CDL Monitor 1 0 Data scan rates for all 408 potential parameters using CDL Monitor 2 0 have be measured at 5 3 seconds This performance is determined by network traffic and engine module configuration but in all cases the update rate is much improved with the new driver CAUTION If you would like to convert your database to CDL Monitor 2 0 contact the actory before attempting In some cases this change will invalidate any mappings associated with the data link However the factory technical personnel can quickly modify the database to avoid this problem Simply email the mvd file to support monicoinc com and request the driver change Section 7 Diagnostic and Event Codes The CDL Gateway now supports the Diagnostic and Event codes from the Data Link To activate support for Diagnostic and Event codes double click on the COMMUNICATIONS tab and click on COLLECT FAULT DATA as shown in figure 7 1 below SIMPLE SOLUTIONS POWERFUL MONITORING n v1 05 6 26 09 1 1 2 20 1 2_AB_LE_CLNT_Custom_H20il_US_1 3 08 Monico DSPLE MonicoView Mima File Edit View Link Help D w amp xu Communications E Monico DSP Driver Selection Programming Port i RS 232 Comms Port Driver CAT Data Link Monitor d RS 485 Comms Port Modbus RTU Slave i 5E statusRawValues Driver Settings m m Block 1 m m Block 2 Ethernet
43. ng in a specific application If absolute minimum update times are required you can use MonicoView to delete the unavailable parameters in the Host Devices to keep scan times to the absolute minimum 20 SIMPLE SOLUTIONS POWERFUL MONITORING n Version 1 1 3 1 1 1 CDL LE GE US 9 9 07 Monico DSPLE MonicoView File Edit View Link Help D we EZ EUER X mi Communications x iic ano uo Option Card Selection Programming Port SNP Master i EB EM PIDStatusValues Option Card CAT Link Option Card sm Block 1 2 f incid m Block4 EI PIDRawValues alll Block 1 H E Block 2 Hm Block 3 wm Block 4 RS 232 Comms Port SNP Master Em USValuesall232 ge Blocki m Block 2 Hm Block 3 m Block 4 H E Block 5 RS 485 Comms Port SNP X Master nm USValuesAll485 m Block 1 H E Block Remove Option Card J E mg Block 3 M Block4 B E Block 5 E Ethernet Close OVER CAPS 5 NUM Figure 6 9 Parameter Status Block Raw Data Block The second Device installed under the RS 232 Programming Device is called PIDRaw Values 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 1s applied or unit conversions are performed Note that in most of the Modbus Versions this block 1s omitted because all values are raw In the PLC versions the raw data is useful for troubleshooting conve
44. ng to IEC 68 2 6 5 to 150 Hz in X Y Z direction for 1 5 hours 2 g s Shock According to IEC 68 2 27 Operational 30 g 11 msec in 3 directions Altitude Up to 2000 meters 7 CONSTRUCTION Case body is burgundy high impact plastic and stainless steel Installation Category I Pollution Degree 2 8 POWER CONNECTION Removable wire clamp screw terminal block Wire Gage Capacity 24 AWG to 12 AWG Torque 4 45 to 5 34 in Ib 0 5 to 0 6 N m 9 MOUNTING Snaps onto standard DIN style top hat T profile mounting rails according to EN50022 35 x 7 5 and 35 x 15 10 CERTIFICATIONS AND COMPLIANCES SAFETY C UL Class I Division II Groups A D Approved for Hazardous Locations UL Listed File E317425 ANSI ISA12 12 01 2007 CSA22 2 No 213 M1987 LISTED by Und Lab Inc to U S and Canadian safety standards UL Listed File E302106 UL508 CSA 22 2 No 14 M05 LISTED by Und Lab Inc to U S and Canadian safety standards IEC 61010 1 EN 61010 1 Safety requirements for electrical equipment for measurement control and laboratory use Part 1 ELECTROMAGNETIC COMPATIBILITY Emissions and Immunity to EN 61326 Electrical Equipment for Measurement Control and Laboratory use Notes 1 Criterion A Normal operation within specified limits 2 This device was designed for installation in an enclosure To avoid electrostatic discharge to the unit in environments with static levels above 4 kV precautions should be taken when the device is moun
45. ogrammer using the following instructions 25 Cor iit CJ TRE SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 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 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 Highlight the first register and double click on FaultSource on the right hand side of the screen The resulting screen will be shown in Figure 7 4 Click OK and then it will ask you how many you want to create This screen is shown in figure 7 5 If you want to capture the last five fault codes then enter five If you want the last 25 fault codes then enter 25 Repeat 1 4 to map registers for each code you wish to capture 1 1 2 20 1 2 AB LE CLNT Custom H20il US 1 3 08 Monico DSPLE MonicoView Fle Edit View Link Deg xmiumaxj n s Communications Help Fm Block 5 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x GenSeti REAL 43 GenSeti REAL 44 GenSeti REAL 45 GenSeti REAL 4 GenSet1_REAL 4 GenSeti_REAL 5 GenSeti REAL 5 GenSeti_REAL S GenSeti_REAL S GenSet1_REAL S GenSeti REAL 70 GenSet1_REAL 71 GenSeti REAL 72 GenSet1_REAL 73 GenSet1_REAL 74 G
46. ol 4 S84 Services T OPC Server CAT Link Option Card E CAT Link Interface CAT Data Link e co E E E E Close Figure 6 7 View Data Blocks 19 CJ ThE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING 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 View Data via USB Data Name DB1003 0000 LONG DB1003 0004 LONG DB1003 0008 LONG DB1003 0012 LONG DB1003 0016 LONG DB1003 0020 LONG DB1003 0024 LONG DB1003 0028 LONG DB1003 0032 LONG DB1003 0036 LONG DB1003 0040 LONG DB1003 0044 LONG DB1003 0048 LONG DB1003 0052 LONG DB1003 0056 LONG DB1003 0060 LONG DB1003 0064 LONG DB1003 0068 LONG Mapping CDL 239 WarningStatus CDL 240 ShutdownsStatus CDL 241 EngineDerateStatus CDL 242_SpareOutputsGSC CDL 243_GeneratorTotalRealPower CDL 244 RelayDriverModuleRelayState CDL 245 GenPhase A RealPower CDL 246 GenPhase B RealPower CDL 247 GenPhase C RealPower CDL 248 GenPhase A ReactivePower CDL 249 GenPhase B ReactivePower CDL 250 GenPhase C ReactivePower CDL 251 GeneratorTotalReactivePower CDL 252 GenPhase A ApparentPower CDL 253 GenPhase B ApparentPower CDL 254 GenPhase C ApparentPower CDL 255_GeneratorTotalApparentPower CDL 256 GeneratorTotalKVvHours Decimal Not Avail Not Avail Not Avail Not Avail Not Avail Not Avail Not Avail
47. opy of the original mvd program before making changes If you click on the UPDATE button before OPENING a valid file or EXTRACTING the existing file it will result in a blank file being downloaded to the Gateway which will render it ineffective If this should occur contact the factory and we can email a copy of the file supplied with the Gateway Please make note of the Version Number on the label on the right side of the Gateway so we can identify the appropriate file When upgrading MonicoView Programmers versions us the REPAIR option The connection is established through a standard USB device cable that has the rectangular connector on one end and the square connector with two rounded edges on the other Make sure to click on LINK OPTIONS and set the connection to USB Installing USB Drivers In some cases connecting a laptop to AC can cause electrical grounding issues In some situations a grounded AC supply on a laptop can cause intermittent errors with the laptop USB port Each time you connect using the MonicoView Software to a new CDL Gateway unit you will see the Windows Found New Hardware screen Make sure to plug in the USB Cable when the Gateway is powered down Upon power up it will then ask for both required drivers to be installed at once First Installation The first installation of the USB drivers from a specific computer will have to be done manually After this first installation on a given PC it will know w
48. or any yellow beside any USB Devices Right click on the item and select Update Driver Select Manual Installation this time and when you are asked to specify the location of the drivers you will choose C Program Files Monico Monicoview Device where the drive letter is the drive you selected when installing the software This should correct the problem and this issue should not happen again This only seems to happen the first time Windows attempts to install the first USB driver on a new PC If this problem occurs it is probably because of laptop USB port issues Therefore before following these instructions disconnect the Gateway from the USB port disconnect the laptop from AC Power reboot the PC and power cycle the Gateway Enabling TCP IP Download Any function accomplished through the USB port can also be performed over an Ethernet Network with the exception of Firmware Upgrades A compact Flash card installed in the Gateway is required to Upgrade Firmware over TCP IP However you must first use the USB connections to enable IP DOWNLOAD under the REMOTE UPDATE section of the Ethernet port Then you must go to LINK OPTIONS and choose TCP IP and enter the IP address of the CDL Gateway From this point you can perform database updates and port setting changes over the LAN Deleting Unwanted Parameters When you expand a Block you will see what parameters are assigned to each register You can delete any parameter
49. put Status 113 Run 174 Stop enerator Synchronizer Control Status GSP P only 30070 Starting at 0 Not installed Inactive Semiautomatic paralleling Permissive paralleling Remote synchronization Remote Synchronization Control Readiness GSP P 30069 DzNot installed 1 ready for remote command only 2 Synchronizing switch not in auto 3 Engine control switch not in auto 4 Engine was not started remotely 5 Engine not 30 CJ TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING 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 Modbus Manual Remarks Id Address Oxygen Sensor Status 30006 Bits set to 1 indicate Status 8 start cal 7 cal in progress 6 sensor on 5 command sensor on its set to 1 indicate Status 8 cal good else cal bad 7 enable cal else disable cal Engine Operation it8 O genset 1 industrial Bit6 O isochronous govenor 1 droop govenor 40 41 46 Auxiliary Status EIS Special Test Status 30052 special test O2disable Bit7 0 proceed to test B Bit5 1 test passed Non zero of tests failed Diagnostic Status Summary 30056 Bits 2 1 0 None 1 Level 1 Warning 2 Level2 Warning Level 3 Warning Bit 3 amp 4 not used Bit 5 0 No logged events 1 At least 1 logged event
50. r each port are individually software programmable up to 115 200 baud RS232 PG Port RS232 port via RJ12 COMMS Ports RS422 485 port via RJ45 and RS232 port via RJ12 DH485 TXEN Transmit enable open collector VoH 15 VDC VoL 0 5 V 25 mA max Ethernet Port 10 BASE T 100 BASE TX RJ45 jack is wired as a NIC Network Interface Card 3 LEDs STS Status LED indicates condition of Data Station TX RX Transmit Receive LEDs show serial activity Ethernet Link and activity LEDs CJ TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING 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 C A Battery Low system variable is available so that the programmer can choose specific action s to occur when the battery voltage drops below its nominal voltage 6 ENVIRONMENTAL CONDITIONS Operating Temperature Range 0 to 50 C Storage Temperature Range 30 to 70 C Operating and Storage Humidity 80 max relative humidity non condensing from 0 to 50 C Vibration Accordi
51. re 6 1 USB Driver Automatic Installation After this screen you will see the screen below stating that the driver you are installing has not been tested by Microsoft Select Continue Anyway Hardware Installation The software you are installing for this hardware G3 Loader has not passed Windows Logo poeng to ant its a Windows XP Tell me why this testing Continuing your installation of this software may impair or destabilize the correct operation of your system either immediately or in the future Microsoft strongly recommends that you stop this installation now and contact the hardware vendor for software that has passed Windows Logo testing Continue Anyway STOP Installation Figure 6 2 Windows Compatibility Warning 4 SIMPLE SOLUTIONS POWERFUL MONITORING n v1 05 6 26 09 Click Finish when this screen 1s done There 1s another driver that will need to be loaded but it will not be found until you download the program to the CDL Gateway M After the initial installation or update of the CDL Gateway M 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 NOTE If your Operating System does not successfully install the drivers you will need to perform this function manually Go to Start and right click on My Computer and choose Manage Then click on Device Manager and look f
52. rsion formulas and each section of the communications network Installing Program Updates If you are sent a program update from the factory you will need to install it using MonicoView First install MonicoView start the program connect the CDL Gateway via the USB port on the front If this 1s the first time you have connected to this particular gateway you will need to install the USB Drivers as shown above After the first driver installation 1s finished go to the file sent to you by the factory and double click on it This 2 SIMPLE SOLUTIONS POWERFUL MONITORING 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 0 In build 444 and above you will have the option to choose either CDL Monitor 1 0 or CDL Monitor 2 0 CDL 2 0 is much faster than the old driver and automatically identifies more engine module configurations without need for manual intervention Also this driver is so fast that the NO RESPONSE DEFERRAL system used in 1 0 was no longer needed Therefore data recover after loss of data link com
53. s 2 1 Diag Code Bits 4 32Coolant Loss Bits 6 5 Emg Stop v1 05 6 26 09 its 8 7 Spare Fault Bits 10 9 High Coolant Temp Bits 12 11 Low Oil Psi Bits 14 13 Overcrank Bits 16 15 Overspeed SC Spare Fault Alarm Status 30095 Organized by bit pairs where for each pair 0 Alarm Off 1 Alarm On 3 Not Available Bits 2 1 Spare Fault 1 Bits 4 3 Spare Fault 2 Bits 6 5 Spare Fault 3 Bits 8 7 Spare Fault 4 16 9 Undefined installed Bits 2 1 Close Breaker Output Bits 4 3 Kilowatt enerator Set Control Output Status GSC only 30149 Organized by bit pairs where for each pair 0 Off de energized 1 On energized 2 Output Fault 3 Output not enerator Set Shutdown Status Extension 1 30112 Active Warning Summary Status it 16 Warning Level 1 Bit 15 Warning Level 2 Bit 14 Warning Level 3 bit value O INACTIVE 1 ACTIVE SC Spare Fault Shutdown Status 30096 Organized by bit pairs where for each pair 0 Shutdown Inactive 1 Shutdown Active 3 Not Available Bits 2 1 Spare Fault 1 Bits 4 3 Spare Fault 2 Bits 6 5 Spare Fault 3 Bits 8 7 Spare Fault 4 16 9 Undefined 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 1s 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 1s active enabled or on Hex to Long Integer The value is con
54. s 10 9 High Coolant Temp Bits 12 11 Low Oil Psi Bits 14 13 Overcrank Bits 16 15 Overspeed SC Spare Fault Alarm Status 30126 Organized by bit pairs where for each pair 0 Alarm Off 1 Alarm On 3 Not Available Bits 2 1 Spare Fault 1 Bits 4 3 Spare Fault 2 Bits 6 5 Spare Fault 3 Bits 8 7 Spare Fault 4 16 9 Undefined SC Spare Fault Shutdown Status 30127 Organized by bit pairs where for each pair 0 Shutdown Inactive 1 Shutdown Active 3 Not Available Bits 2 1 Spare Fault 1 Bits 4 3 Spare Fault 2 Bits 6 5 Spare Fault 3 Bits 8 7 Spare Fault 4 16 9 Undefined enerator Set Control Output Status GSC only 30149 Organized by bit pairs where for each pair 0 Off de energized 1 On energized 2 Output Fault 3 Output not installed Bits 2 1 Close Breaker Output Bits 4 3 Kilowatt Relay Control Output 13 14 Engine Control Shutdown Bits 15 16 High Engine enerator Set Shutdown Status Extension 1 30150 Organized by bit pairs where for each pair 0 Shutdown Inactive 1 Shutdown Active 3 Not Available Bits Active Warning Summary Status 30285 Bit 16 Warning Level 1 Bit 15 Warning Level 2 Bit 14 Warning Level 3 bit value O INACTIVE 1 ACTIVE 39 CJ TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING 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 1s active enabled or on 0 Inact
55. s NOT ACTIVE Engine Derate is ACTIVE bit 1 High exhaust temperature bit 2 High altitude atmospheric pressure bit 3 Air filter plugged bit 4 Engine overspeed E om CJ TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 Monico PID Description Modbus Manual Remarks Id Address bit 5 Low engine coolant temperature bit 6 High engine coolant temperature bit 7 Low engine oil pressure bit 8 High system voltage bit 9 High engine inlet air temperature bit 10 High engine oil temperature bit 11 High hydraulic oil temperature bit 12 No coolant flow bit 13 High aftercooler coolant temperature bit 14 High crankcase pressure bit 15 Fuel filter plugged bit 16 Oil filter plugged bit 17 Not used bit 18 Not used bit 19 Low coolant level bit 20 Alternator NOT charging bit 21 Low fuel level bit 22 High transmission oil pressure bit 23 Low transmission oil pressure bit 24 High transmission oil temperature bit 25 32 Not used writable Bits 26 25 Spare Output All other bit pairs are ndefined 0 OFF 1 ON 16 Output Fault 17 Output not available writable For each group of bits 00 OFF DE NERGIZED 01 ON ENERGIZED 10 Output fault 11 Output not available Don t change state bits 1 2 Undefined future use bits 3 4 2 Undefined future use bits 5 6 2 Undefined future use bits 7 8 2 Undefined future use bits 9 10 Output 9 b
56. s a differential buss that 1s 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 1s no action with these lights after 5 10 seconds then the Data Link is not active or not present Please note that the Caterpillar panel must be powered on for the data link to be active If the Rx light is on solid then the CDL connections are reversed or the cable length is too long If the cable is too long you may need to add a resistor across the terminals on the CDL Gateway M side of the connection to lower the cable impedance Before trying this consult the factory Be sure the Gateway is powered using and isolated 24 VDC source and the EMC wirin uidelines listed in Section 1 are followed or the properly grounded engine batteries o O E 5 1 CD 3 Conne ni L ction Optional 8 Figure 3 1 CDL Connection Pin 7 CDL Pin 8 CDL Section 4 CDL Gateway Host Connections The Host device PLC HMI Building Management System etc 1s connected to the Gateway through one of three host ports The Gateway offers one RS 232 port RJ 11 Jack one RS 485 port RJ 45 Jack and one Ethernet Port RJ 45 Jack Shielded SIMPLE SOLUTIONS POWERFUL MONITORING i v1 05 6 26 09 Host Connection RS 232 via RJ
57. s are covered in the appendix sections of this manual As always you can count on Monico s No Questions Asked support policy We are committed to timely support of every customer who contacts us for help regardless of where the gateway was purchased The only thing that matters to Monico is a successful installation SIMPLE SOLUTIONS POWERFUL MONITORING A GE 24 VDC Power Input v1 05 6 26 09 User Interface over USB RS 485 Port via RJ 45 Jack CDL Input Via RJ 45 Jack R5 232 via RJ 11 Jack Ethernet Connection supports 4 sockets Figure 1 0 Gateway Connections Overview Section 1 Power Supply The CDL Gateway M 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 If this light is blinking then no setup file is installed or it is currently loading a file If this light is solid then a setup file is resident and operating SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 POWER CONNECTION COMMON 24 VDC 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 w
58. s shown in Figure 6 4 below Communications lil Monico DSP Driver Selection Programming Port Modbus RTU Slave PIDSTATUS Driver Modbus RTU Slave Block 1 H RS 232 Comms Port Modbus RTU Slave m Driver Settings IMI Host232 Sirene ces 7 Em Blocki Drop Number 1 mm Block 2 7 5m Block 3 Word Ordering xw Block 4 In Long Blocks Low Then High Fm Block 5 5 0 RS 485 Comms Port Modbus RTU Slave In Real Blocks Low Then High 5 EM Host485 Hm Block 1 r Part Settings E T Urs Baud Rate ERE Beks Data Bits H E Block 5 E t Ethernet Stop Bits m X Protocol 1 Modbus TCP IP Slave IMI HostT CPIP Parity None H E Block1 i m Block 2 Port Mode 2 Wire RS485 r H E Block 3 L Block4 Port Sharing E E Block 5 idiot mmm estas 3 Protocol 2 Share Port No TCP Port Protocol 3 1 Protocol 4 Clear Port Settings Restore Driver Defaults Add Additional Device a Services 2a zr __gose l 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 1f manually configured and the associated Network Mask and Gateway 17 once SIMPLE SOLUTIONS
59. s you will not be using and this will optimize the update rate on the CDL Link Please keep in mind that the CDL Gateway M will normally update all the parameters present on an engine in about 2 3 seconds so for monitoring purposes there 1s usually no need to optimize However if you highlight a register and press the delete button on your keyboard it will remove this parameter Make sure to save an original copy of the program and make changes to the file using another name After making these changes you must choose Link gt Update to send the changes to the CDL Gateway M This is the case with any subsequent changes Please note that you will not be able to change the register locations using the User 15 SIMPLE SOLUTIONS POWERFUL MONITORING n 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 g L ES E F p TIE Lommuricators E I Monico DSP Driver Selection Programming Port Modbus RTU Slave 5 ml PIDSTATUS Driver Modbus RTU Slave Block 1 3 RS 232 Comms Port Modbus RTU Slave Driver Settings
60. site for the latest software revisions before installation The major features are listed below e The CDL Gateway is much faster than the CCM Translator which is used only in conjunction with the CCM Module e The CDL Gateway M Modbus Version offers Modbus RTU over Serial RS 232 and RS 485 as well as Modbus TCP IP over Ethernet All ports are available on the same unit e The CDL Gateway has a User Interface via a USB connection that allows you to configure the ports and see exactly which parameters are responding on your installation e The CDL Gateway has an integral 24 VDC Power Supply e The CDL Gateway is designed to be mounted on Din Rails so no adapters are needed e The CDL Gateway uses modular jacks for connections which minimizes wiring errors especially when using our optional factory cables e The CDL Gateway does not require complicated address offsets e The CDL Gateway does not require complicated Enable Disable Masks as all parameters are default enabled If necessary the user can deactivate individual registers or ports via the User Interface but due to the drastic increase in speed it should not be necessary for monitoring purposes e The CDL Gateway allows for other host protocols such as BACnet and can push parameters directly to Allen Bradley Data Registers or Controller Tags GE Fanuc Analog Input Registers and Siemens Data Blocks via RS 232 RS 485 and Ethernet Special instructions for these version
61. tained in 2 consecutive modbus registers For example if the first value is at address 40001 the value at 40002 will also need to be read Read each register as an unsigned integer Take the first value and multiply by 65536 Then add the second value Multiply the result by the gain and add the offset Long Multiple Status Bits The value is contained in 2 consecutive modbus registers For example if the first value is at address 30001 the value at 30002 will also need to be read Read each register as an unsigned integer Take the first value and multiply by 65536 Then add the second value The result is composed of more than one status condition This is accomplished by setting the appropriate bits for each status condition See details below 32 5 TRE Cor iit SIMPLE SOLUTIONS POWERFUL MONITORING v1 05 6 26 09 Monico PID Description Modbus Manual Remarks eee SS arning Status 30239 Each of the first 24 bits represents warning status 0 Warning is NOT ACTIVE Warning is ACTIVE bit High exhaust temperature bit 2 High altitude atmospheric pressure bit 3 Air filter plugged bit 4 2 Engine overspeed bit 5 Low engine coolant temperature bit 6 High engine coolant temperature bit 7 2 Low engine oil pressure bit 8 High system voltage bit 9 High engine inlet air temperature bit 10 High engine oil temperature bit 11 High hydraulic oil temperature bit 12 No coolant flow bit 13
62. talled bits 1 2 2 Underfrequency bits 3 4 Overfrequency bits 5 6 Undervoltage bits 7 8 Overvoltage bits 9 10 Generator Frequency Sensing Fault bits 11 12 Generator Total Overcurrent bits 13 14 Single Phase Overcurrent bits 15 16 Reverse Power bits 17 18 Undefined future use bits 19 20 Undefined future use bits 21 22 Undefined future use bits 23 24 Generator Freq Inconsistent w Eng Speed bits 25 26 Undefined future use bits 27 28 Undefined future use bits 29 30 Undefined future use bits 31 32 Undefined future use High Exhaust Port Temp Deviating Low Warning 30286 Status indicated by bits 0 4294967295 is Valid Range Each of the first 24 bits represents warning status 0 Warning is NOT ACTIVE 2 Warning is ACTIVE bit 1 Exhaust Temperature Deviating Low bit 2 Exhaust Temperature Deviating High High Exhaust Port Temp Deviating Low Shutdown 30288 Status indicated by bits 0 Shutdown is NOT ACTIVE Shutdown is ACTIVE bit 1 Exhaust Temperature Deviating Low bit 2 Exhaust Temperature Deviating High SIMPLE SOLUTIONS POWERFUL MONITORING i 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 G
63. ted outside an enclosure When working in an enclosure ex making adjustments setting jumpers etc typical anti static precautions should be observed before touching the unit 11 WEIGHT 15 1 oz 456 4 g Immunity to Industrial Locations Electrostatic discharge EN 61000 4 2 Criterion A 2 4 kV contact discharge 8 kV air discharge Electromagnetic RF fields EN 61000 4 3 Criterion A 10 V m Fast transients burst EN 61000 4 4 Criterion A 2 kV power 2 kV signal Surge EN 61000 4 5 Criterion A IkV L L 2 kV L amp N E power RF conducted interference EN 61000 4 6 Criterion A 3 V rms Emissions Emissions EN 55011 Class A v1 05 6 26 09 SIMPLE SOLUTIONS POWERFUL MONITORING 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 TOP 1 60 min clearance Figure 1 Attach Data Station To DIN Rail x 1 00 min clearance BOTTOM Figure 2 1 Hardware Installation DIMENSIONS In inches mm 3 09 78 5 4 15 105 4 5 30 154 7 Figure 2 2 Hardware Dimensions SIMPLE SOLUTIONS POWERFUL MONITORING i 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 i
64. that may occur Startup Routine LED Indication 0 Rapidly Flashing Gateway is currently loading program Gateway is operating normally Table 5 1 STS LED SERIAL HOST PORTS TX RX LED S Rei Rewi Table 5 2 Serial Host Port LED s CDL PORT TX RX LED S Rea Rewms SSS Table 5 3 CDL Port LED s TCP IP ETHERNET PORT LED S LED Indication Yellow Solid Link Established Yellow Flashing Network Activity 10 BASE T Communications 100 BASE T Communications Table 5 4 Ethernet Port LED s These LED s are the first step in troubleshooting communications issues Please note the action of these LED s IN DETAIL when contacting the factory for technical support _12 SIMPLE SOLUTIONS POWERFUL MONITORING k 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 MonicoView is used to adjust port settings for each available port to disable unused ports to maximize performance to delete unused or unavailable parameters from polling blocks and to view live data for all data blocks MonicoView can also be used to modify any section of the unit programming However make sure to use LINK EXTRACT to save a c
65. ure use bits 19 20 Undefined future use bits 21 22 Undefined future use bits 23 24 Generator Freq Inconsistent w Eng Speed bits 25 26 Undefined future use bits 27 28 Undefined future use bits 29 30 Undefined future use bits 31 32 Undefined future use v1 05 6 26 09 1 Warning is ACTIVE bit 1 Exhaust Temperature Deviating Low bit 2 Exhaust Temperature Deviating High High Exhaust Port Temp Deviating Low Shutdown tatus indicated by bits 0 Shutdown is NOT ACTIVE 1 Shutdown is ACTIVE bit 1 Exhaust Temperature Deviating Low bit 2 Exhaust Temperature Deviating High High Exhaust Port Temp Deviating Low Warning 30260 tatus indicated by bits 0 4294967295 is Valid Range Each of the first 24 bits represents warning status 0 Warning is NOT ACTIVE 45 x SIMPLE SOLUTIONS POWERFUL MONITORING i v1 05 6 26 09 Appendix B CDL Gateway CCM Translator Modbus Version Modbus Address Description The CDL Gateway M 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 The Modbus Data Map is available on the Downloads page of the Monico Inc web site www monicoinc com The data map provides extensive details needed for successful installation and operation of the Gatew

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