Transcription
APPL I CAT I O N A N D I NS TAL L AT I O N G U ID EEMCP 4SCADA DATA LINKS
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Table of Contents1GENERAL INFORMATION . 11.11.21.31.42INTRODUCTION . 1OVERVIEW OF EMCP 4 SCADA DATA LINKS . 1REFERENCES . 2GLOSSARY OF TERMS . 3RS-485 SCADA DATA LINK – WIRING AND CONFIGURATION . 52.1NETWORK TOPOLOGY . 52.2WIRING . 6Shielding. 7Termination . 7Extending Range . 72.3SOFTWARE CONFIGURATION . 7Baud Rate . 7Parity . 8Slave Address . 8Stop Bits . 8Bias Resistors . 82.4ERROR CHECKING . 93TCP/IP SCADA DATA LINK – WIRING AND CONFIGURATION . 103.1NETWORK TOPOLOGY . 103.2WIRING (INCLUDING SWITCHES, ROUTERS, ETC) . 10Crossover Cables . 103.3SOFTWARE CONFIGURATION . 11IP Address . 11Network Mask. 11Default Gateway . 113.4ERROR CHECKING . 114EMCP 4 SCADA COMMUNICATION . 134.1ADDRESSING . 134.2SUPPORTED FUNCTION CODES . 134.3DATA INTERPRETATION . 15Numerical data . 15State-based data . 16Complex data . 164.4SECURITY . 165EMCP 4 SCADA DATA POINTS . 195.15.25.35.45.55.65.75.85.95.105.115.12GENERATOR AC MONITORING . 19GENERATOR POWER MONITORING . 20GENERATOR OTHER MONITORING . 21BUS AC MONITORING . 21GENERATOR SET STATE MONITORING AND CONTROL . 21ENGINE MONITORING . 24EVENT MONITORING . 26TIMERS, COUNTERS, TOTALS, AND ENERGY . 28UTILITY MONITORING . 29PROGRAMMABLE CYCLE TIMERS . 30SYSTEM INFORMATION. 30EMCP 4 GSC INPUTS AND OUTPUTS . 31
5.136TROUBLESHOOTING . 346.16.26.37LOAD SHED COMMAND (EMCP 4.3 AND 4.4) . 33INTERMITTENT OR NO COMMUNICATION. 34MODBUS ERRORS: EXCEPTION RESPONSES . 34DATA INVALID – OUTSIDE OF DATA RANGES . 35SCADA PROGRAMMING EXAMPLES . 377.17.27.37.47.57.67.77.8SIMPLE REGISTER READS . 37TWO-REGISTER DATA READS . 38READING INVALID DATA . 38SECURITY – READING AND GAINING ACCESS . 39REAL TIME CLOCK . 41READING ASCII DATA . 41READING AND SETTING VOLTAGE BIAS . 42READING ANALOG INPUTS . 43APPENDIX AMODBUS REGISTER DATA . 49APPENDIX BINDEX OF MODBUS REGISTERS – ALPHABETICAL . 67APPENDIX CINDEX OF MODBUS REGISTERS – NUMERICAL . 73
Application and Installation Guide11.1EMCP 4 SCADA Data LinksGENERAL INFORMATIONINTRODUCTIONThe EMCP 4 is an advanced series of generator set control panels that monitors and controls all aspectsof a generator set. It communicates within the generator set, and to Cat ET, via up to two CAN data links.For customer or site communications, the EMCP 4 features dedicated SCADA data links.TABLE 1-1: SCADA DATA LINKS SUPPORT ACROSS THE EMCP 4 FAMILYEMCP LevelRS-485TCP/IP4.1--4.2 -4.3 4.4 This document details the selection, site planning, configuration, and troubleshooting of the EMCP 4SCADA Data Links.1.2OVERVIEW OF EMCP 4 SCADA DATA LINKSEMCP 4 SCADA data links are intended to provide customers an interface to monitor and control theirgenerator set. They communicate via the Modbus protocol, which is an openly published protocol that hasbecome a de facto standard in industrial communications over the past 30 years.The EMCP 4 supports RS-485 and TCP/IP SCADA Data Links. There are some similarities betweenthem. They both support networking of multiple gensets. They both require unique identifiers (called“Slave Address” in RS-485, “IP Address” in TCP/IP) to be configured in order to uniquely identify eachdevice on the network. They both have length limitations that can be mitigated by using repeaters(repeaters in TCP/IP are built-in to gateways, bridges, hubs, and switches). However, there are alsoseveral differences.The RS-485 SCADA Data Link runs on an RS-485 network, which is a multi-drop bus topology (seesection 2.1). It uses a Modbus master-slave data link, where an EMCP 4 is considered a slave, orRemote Terminal Unit (RTU). This data link is commonly used in legacy applications, and supportedeither natively or via add-on cards by all major PLC platforms. It is also supported (usually via add-onnetwork cards) by most Caterpillar Electric Power products. PCs do not natively support Modbus, butmany PC software are available, either for free or for purchase. The network is RS-485, which is notsupported by most personal computers. However, adapters from either RS-232 or USB are low-cost andeasy to find.The TCP/IP SCADA Data Link runs on a 10BaseT Ethernet network, which is flexible, supporting multipletopologies like bus, star, tree, etc (see section 3.1). It uses the Modbus TCP peer-to-peer data link. Withthe widespread use of TCP/IP networks for the internet as well as corporate networks, Modbus TCP hasbecome quite common. However, it may be more complicated to set up, especially when connecting to anexisting network. It is supported in most newer PLC platforms, but may not be available in legacy PLCsystems. The network is Ethernet, which also uses a multi-drop bus topology. A contrast between RS-485SCADA and TCP/IP SCADA data links is given in Table 1-2. 2010 CaterpillarAll rights reserved.Page 1
Application and Installation GuideEMCP 4 SCADA Data LinksTABLE 1-2: COMPARING RS-485 VS TCP/IP SCADA DATA LINKS1.3PropertyRS-485 SCADATCP/IP SCADADistance4000 ft330 ftSpeed10-56kbps10MbpsTopologybus onlybus, star, etcTerminationrequired at endsnot requiredCommunication modelmaster-slavepeer-peerCabling1-pair plus reference,shielded2-pair twistedMean response time120 ms30 msConfiguration easesimplecomplicatedREFERENCESModbus Application Protocol SpecificationAvailable from www.modbus.orgModbus over Serial Line Specification and Implementation GuideAvailable from www.modbus.orgModbus Messaging on TCP/IP Implementation GuideAvailable from www.modbus.orgEMCP 4.1 and 4.2 Application and Installation GuideLEBE0006, available from Cat PowerNet, under Products EMCP Controls EMCP 4EMCP 4.3 and 4.4 Application and Installation GuideLEBE0007, available from Cat PowerNet, under Products EMCP Controls EMCP 4EMCP 3 Application Note: Reading Event Information via SCADAAvailable from Cat PowerNet, under Products EMCP Controls EMCP 3 A&I Information 2010 CaterpillarAll rights reserved.Page 2
Application and Installation Guide1.4GLOSSARY OF TERMS0b(e.g., 0b1001)0x(e.g., 0xFE03)CANCRCEMCP 4ECMCat ETFMIGSCLEDModbusNULLCHARACTERRMSRS-232RS-485EMCP 4 SCADA Data LinksThe prefix “0b” Indicates that the following digits represent a binary number. e.g.,0b1001 indicates 1001 binary, which is 23 20 9 in decimal.The prefix “0x” indicates that the following digits and characters represent ahexadecimal number. e.g., 0xFE03 indicates FE03 hex, which is 15 212 14 28 3 61440 3584 3 65027 in decimal.Controller Area Network. A serial communications data link with widespread use in thetransportation and power generation indus
interfacing with the user as well as the engine ECM and any other accessory modules. This unit is physically identifiable by its display screen, and a label identifying it as an EMCP 4.1, 4.2, 4.3, or 4.4 Generator Set Controller. See cover page for an image of the EMCP 4.4 GSC. LED Light-Emitting Diode. LEDs on the EMCP 4 include the warning .
