GE Industrial Solutions POWER LEADER ModBus Monitor User Manual

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WARNINGS

CAUTIONS

NOTES

DEH–027

WARNINGS, CAUTIONS, AND NOTES

AS USED IN THIS PUBLICATION

Warning notices are used in this publication to emphasize that hazardous voltages, currents, or other conditions that could cause personal injury exist in this equipment or may be associated with its use.

Warning notices are also used for situations in which inattention or lack of equipment knowledge could cause either personal injury or damage to equipment.

Caution notices are used for situations in which equipment might be damaged if care is not taken.

Notes call attention to information that is especially significant to understanding and operating the equipment.

This document is based on information available at the time of its publication. While efforts have been made to ensure accuracy, the information contained herein does not cover all details or variations in hardware and software, nor does it provide for every possible contingency in connection with installation, operation, and maintenance. Features may be described herein that are not present in all hardware and software systems. GE Industrial Systems assumes no obligation of notice to holders of this document with respect to changes subsequently made.

REFERENCES

GE Industrial Systems makes no representation or warranty, expressed, implied, or statutory, with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warrantees of merchantability or fitness for purpose shall apply.

For details of the Modbus RTU protocol, refer to PI-MBUS-300 Rev. E from Modicon/AEG Schneider Automation. For details of RS-485 communications, refer to the EIA-485 standard.

POWER LEADER™ is a trademark of General Electric Company. Modbus RTU® is a registered trademark of AEG Schneider Automation. Modbus® is a registered trademark of Modicon Inc. Windows and Windows NT are registered trademarks of Microsoft Corporation.

POWER LEADER Modbus Monitor

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Table of Contents

CHAPTER 1 INTRODUCTION

Overview.....................................................................................................................................................................................1

Theory of Operation..................................................................................................................................................................2

PMCS operation ...................................................................................................................................................................2

Monitor operation with PMCS .............................................................................................................................................3

Monitor stand-alone operation..............................................................................................................................................3

Multiple Modbus Monitors...................................................................................................................................................3

Supported Devices......................................................................................................................................................................4

Typical Network Configurations..............................................................................................................................................6

Physical Description ..................................................................................................................................................................7

Specifications..............................................................................................................................................................................8

Environmental............................................................................................................................................................................8

Catalog Numbers .......................................................................................................................................................................8

CHAPTER 2 INSTALLATION

Valid Network Architectures....................................................................................................................................................9

Mounting ....................................................................................................................................................................................9

Control Power Connections....................................................................................................................................................10

Grounding...........................................................................................................................................................................10

RS-485 Connection(s)..............................................................................................................................................................10

RS-485 Termination Considerations...................................................................................................................................11

Software Installation ...............................................................................................................................................................12

Modbus Monitor Configuration Tool .................................................................................................................................12

Modbus Monitor Proxy.......................................................................................................................................................13

Maintenance.............................................................................................................................................................................13

CHAPTER 3 CONFIGURATION

Modbus Monitor Configuration Tool....................................................................................................................................15

Notes on Modbus Monitor Configuration Tool Keyboard Interface ..................................................................................17

Device Table.......................................................................................................................................................................18

Groups ................................................................................................................................................................................21

Communication Timeout Setting........................................................................................................................................22

Port Configuration Settings.................................................................................................................................................22

Advanced Configuration.........................................................................................................................................................22

Read Files from a Monitor..................................................................................................................................................22

Write Files to a Monitor .....................................................................................................................................................24

Print Files............................................................................................................................................................................24

PC to Monitor Connection......................................................................................................................................................25

PC-Monitor Communications.................................................................................................................................................25

Monitor Setup Menu ...............................................................................................................................................................26

Program Upgrade................................................................................................................................................................26

Screen Saver Configuration................................................................................................................................................26

Set Password.......................................................................................................................................................................27

RS-485 Port Configuration.................................................................................................................................................27

Auto-Detection for SLT......................................................................................................................................................27

Set Date & Time.................................................................................................................................................................27

POWER LEADER Modbus Monitor

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Table of Contents

CHAPTER 4 OPERATION

Introduction..............................................................................................................................................................................29

Keypad/Menu Navigation .......................................................................................................................................................29

Main Menu...............................................................................................................................................................................29

Look at a Device.................................................................................................................................................................30

Look at the Local Event Log...............................................................................................................................................32

PMCS Event Log................................................................................................................................................................33

Notes on Password Protection.................................................................................................................................................30

Using the Modbus Monitor with PMCS ................................................................................................................................33

CHAPTER 5 ERRORS AND DIAGNOSTICS CHAPTER 6 TROUBLESHOOTING GUIDE CHAPTER 7 ADVANCED CONFIGURATION

Step 1: Define a New Device Type..........................................................................................................................................41

Step 2: Define the Device Type as Hybrid or Generic .........................................................................................................42

Step 3: Create the Device Type’s Register Map...................................................................................................................42

Add Register.......................................................................................................................................................................43

Modify Register..................................................................................................................................................................43

Delete Register....................................................................................................................................................................43

Utilized Register Block List (URBL)......................................................................................................................................43

Step 4. Customize the Display.................................................................................................................................................44

Notes on Hybrid/Generic Device Types .................................................................................................................................45

Special Handling Registers.................................................................................................................................................45

Hybrid Device Types..........................................................................................................................................................45

Generic Device Types.........................................................................................................................................................46

Defining Hybrid and Generic Device Types.......................................................................................................................46

Defining the Register Set....................................................................................................................................................46

35 37 41

APPENDIX A: MODBUS PROTOCOL

Implementation Basics.............................................................................................................................................................49

Modbus RTU Message Format...............................................................................................................................................49

CRC-16 Algorithm..............................................................................................................................................................50

Message Framing and Timing.................................................................................................................................................50

Register Groupings..................................................................................................................................................................50

Data Conventions.....................................................................................................................................................................51

Format for Floating Point and Long Integer Data Types ....................................................................................................51

APPENDIX B: MODBUS MONITOR REGISTER MAP APPENDIX C: REGISTER DATA FORMATS SUPPORTED BY THE MODBUS MONITOR APPENDIX D: SUPPORTED FIRMWARE REVISIONS FOR TID’S GLOSSARY

53 55 51 60

POWER LEADER Modbus Monitor

List of Figures and Tables

List of Figures

Figure 1. POWER LEADER Modbus Monitor. ...............................................................................................................1

Figure 2. PMCS DDE communications cycle...................................................................................................................2

Figure 3. Monitor Proxy and PMCS DDE communications.............................................................................................3

Figure 4. Monitor acting as master to a network of POWER LEADER devices. ............................................................6

Figure 5. Typical PMCS network incorporating Monitor. ...............................................................................................6

Figure 6. Front view of Monitor, showing dimensions.....................................................................................................7

Figure 7. Side view of the Monitor, showing dimensions and connections.....................................................................7

Figure 8. Valid Modbus Monitor network architectures. .................................................................................................9

Figure 9. Cutout pattern for mounting the Monitor........................................................................................................10

Figure 10. RS-485 port and RS-485 connector pinouts..................................................................................................11

Figure 11. RS-485 Terminations.....................................................................................................................................11

Figure 12. RS-485 network wiring..................................................................................................................................12

Figure 13. Removing the cooling fan filter.....................................................................................................................13

Figure 14. Configuration Tool main screen....................................................................................................................16

Figure 15. Configuration Tool View dialog. ..................................................................................................................16

Figure 16. New Configuration screen.............................................................................................................................17

Figure 17. Port Configuration screen..............................................................................................................................17

Figure 18. Modify Configuration screen. .......................................................................................................................18

Figure 19. Configuration Tool Device Table screen. .....................................................................................................18

Figure 20. Add a Network Device dialog. ......................................................................................................................19

Figure 21. Select PMCS Topic File dialog.....................................................................................................................20

Figure 22. PMCS Configuration information screen......................................................................................................20

Figure 23. AutoDetect dialog box...................................................................................................................................20

Figure 24. Configuration Tool Group Configuration screen..........................................................................................21

Figure 25. Add New Group screen. ................................................................................................................................21

Figure 26. Modify Groups screen...................................................................................................................................22

Figure 27. Configuration Tool Operational Parameters screen......................................................................................22

Figure 28. Monitor Configuration Tool: Read Configuration dialog.............................................................................22

Figure 29. Device Types Result Log. .............................................................................................................................24

Figure 30. Monitor Configuration Tool Write Configuration dialog. ............................................................................24

Figure 31. Monitor Configuration Tool’s Print dialog...................................................................................................25

Figure 32. PC to Monitor RS-232 connection. ...............................................................................................................25

Figure 33. Monitor Main menu.......................................................................................................................................25

Figure 34. Monitor Setup menu......................................................................................................................................26

Figure 35. Monitor Keypad.............................................................................................................................................29

Figure 36. Monitor Main menu (details).........................................................................................................................29

Figure 37. Monitor View menu.......................................................................................................................................30

Figure 38. Device Groups screen....................................................................................................................................30

Figure 39. Monitor Devices list......................................................................................................................................31

Figure 40. Device Data screen........................................................................................................................................31

Figure 41. Monitor View Devices menu structure..........................................................................................................32

Figure 42. Sample Event Log screen. .............................................................................................................................32

Figure 43. Monitor Diagnostics Menu............................................................................................................................35

Figure 44. Monitor Configuration Tool: New Device Type dialog................................................................................41

iii

POWER LEADER Modbus Monitor

Figures and Tables

Figure 45. Save As.... dialog box....................................................................................................................................42

Figure 46. Monitor Configuration Tool: Modify Device Types dialog. ........................................................................42

Figure 47. Monitor Configuration Tool: Register Map dialog.......................................................................................42

Figure 48. Monitor Configuration Tool: Add Register dialog box................................................................................43

Figure 49. Customize Display dialog box. .....................................................................................................................44

Figure 50. Assign/Unassign Registers dialog.................................................................................................................44

Figure 51. Insert Screen dialog.......................................................................................................................................45

List of Tables

Table 1. Devices supported by the Monitor. ....................................................................................................................5

Table 2. Monitor specifications........................................................................................................................................8

Table 3. Monitor environmental requirements.................................................................................................................8

Table 4. Monitor catalog numbers....................................................................................................................................8

Table 5. Device firmware revisions supported by the Modbus Monitor........................................................................59

POWER LEADER Modbus Monitor

Chapter 1

Introduction

Chapter 1 – Introduction

Overview

The GE POWER LEADER Modbus Monitor, shown in Figure 1, is a microprocessor-based device that connects to an industry-standard Modbus RTU network, implemented on RS-485 wiring. The Monitor tracks metering and status information collected by GE POWER LEADER power management devices and a variety of third-party power management devices. The Monitor provides a convenient station for viewing of data from remote devices.

Figure 1. POWER LEADER Modbus Monitor.

Modbus RTU networks are designed on a master-slave architecture. Only one master per network is permitted. The master queries the slaves when it needs their data, and slave devices may only communicate on the network in response to a request from the master.

The Monitor can operate in either of two roles. First, it is capable of acting as a master on one or two Modbus segments of power management devices, collecting data from the devices for local display, as shown in Figure 4.

Second, it is capable of behaving as a “second-incommand” to GE’s Power Management Control System (PMCS), as shown in Figure 5. In this role, the Monitor resides on the RS-485 network with other POWER LEADER devices, performing its monitoring duties but behaving as a slave device to the PMCS master. However, if the master is disabled for some reason, perhaps a computer problem or a power failure at the host PC, the Monitor will immediately and transparently assume the role of master to the other devices.

NOTE: The POWER LEADER Modbus Monitor is compatible only with GE Power Management Control System software, version 5.1, version 6.0 or greater. It is not certified to be compatible with any other host software.

Once installed and wired to control power and network connections, the Monitor must be configured for communications (Modbus address, baud rate, etc.) on the RS-485 network. It must also be configured with the identity and type of the other network devices. This configuration is performed using a software application, the Modbus Monitor Configuration Tool, running on a PC. When you are ready to download the configuration to a Monitor, you’ll connect the PC to the communications port on the Monitor’s front panel using an RS-232 straight-through cable (provided with Monitor).

NOTE: In this manual, the term SEGMENT or MODBUS SEGMENT will refer to a single RS-485 communications network operating under the Modbus protocol. A Monitor may be connected to one or two Modbus segments, depending on whether it is a single or dual port version.

POWER LEADER Modbus Monitor

Chapter 1 – Introduction

Theory of Operation

As mentioned previously, the POWER LEADER Modbus Monitor has two modes of operation. It can operate as a stand-alone master to one or two Modbus segments of compatible devices or it may operate in conjunction with the GE Power Management Control System (PMCS) software. In this second mode, the Monitor collects the data it needs to display and also watches for the PMCS to go off-line. If for some reason the Monitor does not sense the PMCS being online as Modbus master, the Monitor will immediately and transparently assume the role of master on the Modbus segment(s).

We’ll explain briefly how PMCS operates, and then the relationship of the Monitor to the PMCS, and finally the operation of the Monitor independent of PMCS.

PMCS operation

The GE Power Management Control System consists of four basic parts: (1) power management devices, (2) an RS-485 network (“Modbus segment”) connecting these devices to (3) a host computer running GE’s Power Management Control System software and a Dynamic Data Exchange (DDE) server, which monitors the devices for data requested by (4) client software programs, and feeds this data back to the clients requesting it.

The power management devices vary in complexity and intended use, but in general their function is similar: they collect data on specific electrical metered, status and event parameters (volts, amps, power consumption, peaks, trips, etc.). The various information they monitor is recorded in specific memory locations called registers. Registers are organized by address. The complete list of a devices’ registers, their addresses and their contents is referred to as a register map.

PMCS has been preprogrammed with the register maps of a variety of GE and third party devices. When the user configures PMCS with the details of what devices are connected to his network, the software automatically associates the appropriate register map with the given device type. This enables the software to locate information in a device based on its type.

PMCS operates using a client-server architecture called DDE - Dynamic Data Exchange. DDE is a means of exchanging information between software programs operating on a PC. Client programs request information from a Server program; the Server program fills these requests. In the case of the PMCS DDE Server, these requests are for power management information being gathered by physical power management devices on Modbus segments connected to the PC. An example of PMCS DDE communications is shown in Figure 2.

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Client software such as the PMCS Event Logger or Waveform Capture is used to analyze particular data from devices. Each client program needs particular pieces of data from particular devices. The client sends a DDE request to the Server, the Server queries the devices for the requested information, and when it has received the information from the devices, it replies to the client’s request with the desired information.

An important aspect of DDE is its ‘dynamic’ nature; once a client has requested information from the Server, a ‘DDE link’ to that data is established. The Server will continue to monitor that information and, if any changes occur, will forward the new data to the client.

Monitor operation with PMCS

POWER LEADER Modbus Monitor

Chapter 1 – Introduction

The Proxy’s role in assisting the Monitor in DDE communications is shown in Figure 3.

The Monitor’s place in this scenario is as a backup device to the PMCS software on the host computer, and also as a remote monitor, enabling viewing of PMCS device data at locations other than the host PC.

When the PMCS DDE Server is present on a network, Monitors on the network operate as slaves to the PMCS system acting as master. Because Modbus networks operate on a master-slave architecture, which allows only the master device to initiate communications, a Monitor cannot directly request information from the devices it needs to track. A special client application called the Monitor Proxy provides the means for a Modbus Monitor to obtain the data it requires from network devices. The Proxy runs on the host PC alongside the PMCS DDE Server.

When the Monitor Proxy application is launched, its first task is to query the PMCS DDE Server, checking for any Monitor devices on the segment. If Monitor devices are found, the Proxy records their device names and then asks the DDE Server for each Monitor’s request list information. The Monitor’s request list is a listing of all devices and specific data the Monitor needs to display. The Monitors send their request lists back to the Server, which passes this information on to the Monitor Proxy, completing the DDE transaction.

The Proxy now knows which devices each Monitor needs to track for data and events. The Proxy uses the information in the Monitor’s request lists to establish DDE links with the Server for the devices and corresponding registers. The Server begins polling these devices for data and sending the data back to the Proxy.

As a slave device, the Monitor cannot initiate communications or requests for data. However, there is nothing to prevent the Monitor from ‘eavesdropping’ on network traffic. The Monitor watches the segment for requests to and responses from the devices it is supposed to track and uses this information to update its displays.

The Proxy itself has no need for the data from the devices, since its purpose is merely to create the conversation so that the Monitor can eavesdrop on the reply. The Proxy discards all device data received from the DDE Server.

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The Proxy can also send the PMCS event log to a Monitor when requested. The Monitor can store the latest 50 PMCS events if the PMCS Event Logger client is running on the host PC with the DDE Server.

Monitor stand-alone operation

To a limited degree, the Monitor functions in a manner very similar to the PMCS DDE Server, acting as master to a network of power management devices.

The Monitor has been preconfigured with the register maps of a variety of GE and third-party power management devices. The user programs the Monitor with the Modbus addresses and device types of the devices on the segment(s), and tells the Monitor what information he wishes to monitor from each device. The Monitor will query the devices for the desired data and display it on-screen.

Multiple Modbus Monitors

Up to two Modbus Monitors are permitted on a single segment. In compliance with the Modbus master-slave architecture, only one device may act as master at a given time. However, while one Monitor is acting as master, the second Monitor is constantly checking for the master’s presence. Should the master go off-line, the second Monitor will immediately assume the role of master device.

POWER LEADER Modbus Monitor

Chapter 1 – Introduction

Supported Devices

The Modbus Monitor supports three classes of power management devices: tightly integrated devices, generic devices, and hybrid devices.

Tightly integrated devices are those device types which are predefined in the Monitor. The Monitor has a copy of these devices’ register maps in its memory, and knows precisely where to find any data it needs from such a device. The register maps of tightly integrated devices may not be changed in any way. The display screens of tightly integrated device types are also pre-defined and may not be changed (see hybrid devices, below, for more information on customizing displays).

Generic devices are user-defined. The Modbus Monitor supports any power management device with registerbased Modbus RTU communications via RS-485. To set up a generic device, the user must manually enter the register map (or those parts of interest) into the Modbus Monitor via the Monitor Configuration Tool (see Chapter 7, Advanced Configuration). In contrast to the tightly integrated devices, whose register maps have already been programmed into the Monitor, the Monitor knows nothing about a generic device until the user

enters this data. Event recording and special handling registers are not supported for generic device types.

The third type of device supported by the Monitor is the hybrid device. This device type is derived from a tightly integrated device, but is not as loosely defined as a generic device. A hybrid device type’s register map and display screens are copied from the register map of a tightly integrated device, but they may be modified like a generic device. This allows some flexibility to be supported by the Monitor without giving up the convenience of pre-defined tightly integrated devices. The display screens of tightly integrated devices may be customized by creating a new hybrid device type based on the tightly integrated device type in question, and then modifying the display portion of the device type. Chapter 7, Advanced Configuration, discusses the creation and configuration of generic and hybrid device types.

The Monitor supports up to 31 device types, including the 21 tightly-integrated devices shown in Table 1. All tightly integrated devices are fully supported by PMCS

6.0; a sub-set (devices indicated by an asterisk) is supported by PMCS 5.1.

POWER LEADER Modbus Monitor

Chapter 1 – Introduction

Device Name as displayed on Monitor

screen

POWER LEADER EPM* PL EPM Metering POWER LEADER Meter* PL Meter Metering EPM 3710* EPM 3710 Metering EPM 3720* EPM 3720 Metering MULTILIN Power Quality Meter (PQM)* Multilin PQM Metering POWER LEADER MDP Overcurrent Relay* MDP Relay Protection Spectra MicroVersaTrip™ * Spectra MVT PM Protection Enhanced MicroVersaTrip™ C* Enhanced MVT PM (RMS9C) Protection Enhanced MicroVersaTrip™ D* Enhanced MVT PM (RMS9D) Protection Spectra ECM™ Electronic Control Module* Spectra ECM Protection/Control MULTILIN 239 Motor Protection Relay* Multilin 239 Protection/Control MULTILIN 269 Plus Motor Management Relay* Multilin 269 Protection/Control MULTILIN SR469 Motor Management Relay* Multilin 469 Protection/Control MULTILIN SR489 Generator Management Relay* Multilin 489 Protection/Control MULTILIN 565 Feeder Management Relay* Multilin 565 Protection/Control MULTILIN 735 Feeder Relay* Multilin 735 Protection/Control MULTILIN SR745 Transformer Management Relay* Multilin 745 Protection/Control MULTILIN SR750 Feeder Management Relay* Multilin 750 Protection/Control MULTILIN SR760 Feeder Management Relay Multilin 760 Protection/Control System Monitor SM-3 Voltage Regulator SM3 Protection/Control EPM 7300 PML7300 Protection/Control

Function

Table 1. Devices supported by the Monitor.

POWER LEADER Modbus Monitor

Chapter 1 – Introduction

Typical Network Configurations

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Physical Description

Figure 6 and Figure 7 show the dimensions of the Monitor. The important features of the Monitor are listed below:

• The Monitor’s front panel display is used for viewing device data and event messages during operation, for diagnostics purposes, and for some very limited configuration capabilities.

• The keypad is located directly beneath the display. Ten keys are used for navigating the menus of the Monitor.

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POWER LEADER Modbus Monitor

Chapter 1 – Introduction

• A set of three terminals for AC or DC control power input are provided on the side of the case.

• A grounding screw is provided above the control power connection.

• Two five-terminal connectors on the side of the case provide daisychained RS-485 input and output connections to one or two Modbus segments.

• The on/off switch for the Monitor is located on the side of the case above the RS-485 connectors.

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Figure 6. Front view of Monitor, showing dimensions.

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POWER LEADER Modbus Monitor

Chapter 1 – Introduction

Specifications

The specifications of the Modbus Monitor are listed in Table 2.

Parameter Value

Control power 100–240 Vac, 50, 60 Hz;

125–250 Vdc;

30 W min Current draw for fusing Use 1.5A – 3.0A slow-blow fuse Modbus communications Two RS-485 ports, 1200 baud, 2400 baud, 4800

baud, 9600 baud, and 19.2 Kbaud supported; no

parity, eight data bits, one stop bit.

Mating connector: Precision Connector Designs

(PCD) ELFT03260 or equivalent (supplied with

unit) RS-485 Modbus

interconnections Standards: UL 508, File No. E146421

Device types supported The Monitor supports up to 32 device types,

Devices per Modbus segment

Compatible Modbus RTU Host Software

Bare wire, AWG #12–24

CSA: C22.2 No. 14, File No. LR-77871-25

including the 21 Tightly Integrated Device types

and the Modbus Monitor device type itself.

Per the Modbus standard, up to 32 total ‘drops’

(devices) per segment,

applicable) PMCS host.

Up to 215 commnet devices may be supported via

Modbus Concentrators.

See GEH-6502,

Guide

, for details.

GE Industrial Systems

Power Management Control System, version 5.1 or

greater

including

Monitors and (if

PMCS Network Architecture

Environmental

The environmental requirements of the Monitor are listed in Table 3.

Parameter Value

Operating temperature 0° C to +65° C Storage temperature –20° C to +80° C Relative humidity 5% to 95% noncondensing Environmental exposure NEMA 12 Vibration response and

endurance Fast transient surge ANSI C37.90.1 Radiated EMI withstand ANSI C37.90.2 Electrostatic discharge IEC 801–2

Table 3. Monitor environmental requirements.

IEC 255–21–1

Severity Class 1

Severity Class 4

Catalog Numbers

Two versions of the Monitor are available: a single RS485 port version and a dual RS-485 port version. Catalog numbers for each version are shown in Table 4.

Description Catalog Number

Monitor, single RS-485 port PLMNTR1 Monitor, dual RS-485 port PLMNTR2

Table 4. Monitor catalog numbers.

Table 2. Monitor specifications.

Chapter 2

Installation

The installation of a Monitor is straightforward and relatively simple. The device is mounted in an appropriate cutout in switchgear or a panelboard, control power and grounding connections are made, and the RS485 connections to one or two Modbus segments are made. Software necessary to configure the Monitor must be installed on a PC. Finally, if the Monitor is to be used as part of a PMCS system, a special client software package called the Modbus Monitor Proxy must be installed on the host PC where PMCS runs. This chapter presents the instructions for each of these procedures.

Valid Network Architectures

There are only four permissible network architectures with which the Modbus Monitor may be used. Select the architecture appropriate for the network you have designed. Refer to GEH-6502, the POWER LEADER PMCS Network Architecture Guide for information on designing RS-485 networks. These are shown in Figure 8, below.

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POWER LEADER Modbus Monitor

Chapter 2 – Installation

DUAL PORT MONITOR USERS:

DO NOT CONNECT THE MONITOR’S TWO RS-485 PORTS TO THE SAME MODBUS SEGMENT. This will cause communications errors and misoperation of the Monitor.

Example A shows a single Modbus Monitor wired to a single Modbus segment. Example B shows the same monitor in a dual-port version, wired to two different Modbus segments.

Examples C and D illustrate fully loaded Modbus segments - no more than 2 Monitors are permitted on a given Modbus segment.

Example C illustrates a pair of Monitors connected to a single Modbus segment. In this example, the Monitors may be either single port or dual-port versions, provided both are the same. You may not mix single-port and dual-port Monitors on a Modbus segment (see note below.)

Example D shows the same pair of Monitors wired to a second Modbus segment.

IMPORTANT: With regard to Example C (two Monitors on a single RS-485 segment) it is NOT permissible to mix different models of Monitors on a segment. Monitors #1 and #2 MUST be of the same model, either both single-port or both dual-port.

The nature of the other network architectures makes this concern irrelevant for examples A, B and D, since in Example A you could have either a single or a dual port Monitor, and in Examples B and D, you may only use a dual-port monitor(s).

Figure 8. Valid Modbus Monitor network architectures.

WARNING: Any other wiring of the Modbus Monitor may result in incorrect operation and errors.

Mounting

The hole pattern for mounting the Monitor in switchgear is shown in Figure 9. Insert the Monitor through the mounting hole, being careful to line up the six faceplate studs with the six holes drilled in the panel. From the

POWER LEADER Modbus Monitor

Chapter 2 – Installation

back of the panel, apply the lock washers and mounting nuts (included with the Monitor) to the studs. Hand tighten them with a small wrench.

Be sure to allow clearance behind the unit so that the fan can operate effectively and along the bottom of the unit where the ventilation vents are located. A minimum of

0.25 inch must be allowed.

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WARNING: Failure to properly connect earth ground may result in voltages hazardous to personnel and equipment being present at the Monitor enclosure.

RS-485 Connection(s)

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Control Power Connections

Control power connections are made on the side of the case. The connectors are labeled H+, N-, and GND. The appropriate power cable terminations are spade lugs on AWG #12–18 wire. See Table 2 for control power voltage ranges. Hand-tighten connection screws with a Phillips head screwdriver.

On the side of the Monitor case are two five-pin connectors labeled Modbus Segment A and Modbus Segment B.

NOTE:

Both connectors are present and labeled regardless of whether the individual Monitor is a single or dual port version. In the single port version, the Segment B connector is disabled.

Mating connectors (one for each segment) are included with the Monitor for customer connection. The pinout for assembling the mating connector is shown in Figure

10. If the Monitor is to be the first or last device on the RS-485 network, it must be terminated using the enclosed terminating resistor. Place the resistor between the appropriate + and - connections on the mating connector. (See below for details on RS-485 termination).

Grounding

The Monitor chassis should be connected to earth ground for personnel safety reasons. Connect earth ground to the green-colored grounding screw on the side of the Monitor enclosure. Earth ground connection requires #14 AWG or thicker wire and a ring or spade lug.

POWER LEADER Modbus Monitor

Chapter 2 – Installation

When the assembly is complete, plug the connector into port labeled Segment A on the side of the Monitor, as shown in Figure 10.

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Figure 10. RS-485 port and RS-485 connector pinouts.

The connectors labeled

should be wired to the cable

coming from the host (or previous device), or should be terminated if the Monitor is the first device on the Modbus segment. The

RS-485 IN

connector of the next Modbus device, or

connectors are wired to the

OUT

terminated if the Monitor is the final device on the Modbus segment. Please study and follow the RS-485 grounding considerations and termination rules below to ensure the correct operation of your Modbus segments.

If the Monitor is to be connected to a second Modbus segment, follow the procedures outline above to wire the connector, and plug it into the port labeled

Segment B

on the side of the Monitor. Note that

Modbus

termination considerations are independent for each segment; i.e., the Monitor may need to be terminated for one or both RS-485 segments, or for neither, if it is positioned in the middle of the segment(s).

Figure 11 illustrates appropriate termination of an RS485 segment at the Modbus Monitor

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RS-485 Termination Considerations

Per the EIA485 standard, every RS-485 network must be terminated at both ends. If the Modbus Monitor is the first device, place the supplied 120-ohm, 1/2-watt resistor between the + and - connectors of the port. If the Modbus Monitor is the last device, place the supplied 120-ohm, 1/2-watt resistor between the + and connectors of the

RS-485 OUT

port.

RS-485 IN

POWER LEADER Modbus Monitor

Chapter 2 – Installation

RS-485 Grounding Considerations

Figure 12 illustrates correct wiring for communications and shield grounding. By following this example, a secure grounding point will be provided for each device on the network. Any surge will dissipate locally without being carried up or down the network to other devices, thus minimizing the chance for damage to devices due to surge or EMI.

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The RS-485 shield is attached to ground at the host. The shield is not connected to the RS-485 IN port of the next device, but is connected to the RS-485 OUT port and to a grounding screw if the shield terminal of the RS-485 port is not directly grounded. This procedure provides an isolated ground for each device.

IMPORTANT: The Modbus Monitor’s shield terminal is not directly grounded. If you wish to connect the RS-485 shield to ground at the Monitor, you must also make a connection from the shield terminal to the grounding screw on the Monitor’s case. Use AWG #12-14 wire for this connection.

Software Installation

Modbus Monitor Configuration Tool

Configuration of the Monitor requires a Windows-based software program, the Modbus Monitor Configuration Tool. This program is included with the Modbus Monitor, on several 3.5” high density floppy disks. This section describes installation of this software onto a PC. A laptop PC’s portability lends itself well to this use if configurations are to be downloaded to Monitors already installed in the likely facility-floor setting. However, it is acceptable to create configuration files on a desktop PC and then copy the files to a laptop for transportation to the Monitor’s location.

The Configuration Tool requires a 486 or better PC running Windows 3.1x, at least 8 megabytes of RAM, and a floppy drive for installing the Configuration Tool from the floppy disk. A minimum of 15 megabytes of hard disk space is required to install the Configuration Tool. A mouse is recommended for ease of use, but not required.

To install the Monitor Configuration Tool on the selected PC:

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1. Power up the PC and launch Windows. Start the Windows Program Manager.

2. Insert the Monitor Configuration Tool disk labeled “DISK 1”.

3. Select Run from the Program Manager’s File Menu.

4. Enter A:\setup.exe and press return.

POWER LEADER Modbus Monitor

Chapter 2 – Installation

A new program group with the name Modbus Monitor Configuration Tool will be created. In it will be a README file and the Configuration Tool application. Double-click on the application’s icon to launch the Configuration Tool.

Modbus Monitor Proxy

For the Modbus Monitor to function in slave mode in a PMCS system, the Modbus Monitor Proxy client program must be installed on the host PC where the PMCS DDE Server is running. Complete the PMCS installation, then perform the Proxy installation as described below. The Modbus Monitor Proxy program is included with the Modbus Monitor on 3.5” high density floppy disk(s).

NOTE: PMCS requires the Windows NT 4.0 operating system, therefore the Modbus Monitor Proxy also requires NT 4.0.

To install the Modbus Monitor Proxy:

Maintenance

The Modbus Monitor requires very little operational maintenance due to its heavy-duty industrial construction. However, it is recommended that the cooling fan filter be cleaned periodically to prevent unnecessary heat buildup inside the Monitor case.

To clean the fan filter, remove the plastic gasket from the rear of the Monitor case, then remove the fan filter itself, as shown in Figure 13. Gently vacuum or shake the filter to remove any accumulated dust or debris, or blow the debris off using a can of compressed air. Replace the filter and gasket when cleaning is complete.

1. Log in to Windows NT on the host PC.

2. Insert the Modbus Monitor Proxy disk labeled Disk 1.

3. Select Run from the Windows NT Start menu.

4. Enter A:\SETUP and hit return.

Follow the on-screen instructions. The installer will prompt you to select a directory to install the Proxy in. The default is C:\Monitor.

You will be prompted to locate the PMCS DDE Server’s .ini file. This file is usually located in the WINNT\ directory and will have the name GE32MODB.ini or GE32ENET.ini.

If you’re using the PMCS Event Logger client program, you’ll also be asked to locate the directory where the Event Logger database file is located. The file name is EventLog.mdb and is usually located in the directory GE_PMCS\EventLog\ .

To use the Proxy, launch the application from the Start menu. You’ll find an icon for the program named GE Modbus Monitor Proxy. Launching the Proxy application automatically starts the PMCS DDE Server.

Figure 13. Removing the cooling fan filter.

POWER LEADER Modbus Monitor

Chapter 2 – Installation

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POWER LEADER Modbus Monitor

Chapter 3

Configuration

Chapter 3 – Configuration

After installing the Modbus Monitor, some initial configuration is required to set up the Monitor for communications. Communications settings such as baud rate, parity, and Modbus address must be set to correspond with the network’s settings.

Once the Monitor has been successfully configured for network communications, it must also be configured for its task: monitoring the other devices on the network. To successfully monitor other devices on the Modbus segment(s), a Monitor must know the Modbus addresses and device types of all the devices on the segment(s).

These configuration tasks require the use of the Modbus Monitor Configuration Tool, a Windows-based software program included with the Modbus Monitor.

The Modbus Monitor Configuration Tool is used to create a “profile” of the Monitor, consisting of all the different configurable attributes, such as communications settings, information on devices connected to the Modbus segment(s), the register maps for these devices, etc.

Once the desired profile has been established, it can be downloaded to the Monitor via the RS-232 port on the Monitor’s front panel. When a new profile has been downloaded to the Monitor, the old profile will be replaced and the new profile will take effect.

This chapter will cover using the Configuration Tool to create a profile for the Monitor and how to download the profile to the Monitor. Later in the chapter, we’ll discuss what other configuration options are available from the

Monitor’s display/keypad, not requiring the Configuration Tool.

Modbus Monitor Configuration Tool

First, launch the Monitor Configuration Tool from the Windows Program Manager. The Modbus Monitor Configuration Tool main window will appear (Figure

14). There are three pulldown menus available from the main

screen of the Configuration Tool. The first, File, offers standard options to create a new database of Monitor configurations, open an existing database, or create a new database by Saving the current database As… under a new file name. Within one database, you may have many Monitor configurations. This allows you to group configurations by project or customer; for instance, you might have a file called Customer_A and within that file, there might be configurations named Plant 1 Monitor 1, Plant 1 Monitor 2, Paint Shop Monitor, etc.

The Configuration pulldown menu offers access to the Print dialog box (discussed later in this chapter) and the View dialog box, which permits you to create, modify or delete configurations within a database. The View dialog box is shown in Figure 15.

The third pulldown menu, Help, offers the standard Contents item, which accesses the Configuration Tool’s HELP table of contents, and the About dialog, which gives information about the version of the Configuration Tool you are using.

+ 47 hidden pages

GE Industrial Solutions POWER LEADER ModBus Monitor User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Overview

Theory of Operation

Supported Devices

Typical Network Configurations

Physical Description

Catalog Numbers

Valid Network Architectures

Mounting

RS-485 Connection(s)

Control Power Connections

Software Installation

Maintenance

Modbus Monitor Configuration Tool