Info@dsl-Electronic - de WWW - Dsl-Electronic - de

1
DSL-electronic® GmbH , Schiricksweg 2, D 41751 Viersen

Tel: +49-2162-400 25, Fax: +49-2162-400 35
info@dsl-electronic.de, www.dsl-electronic.de / www.dsl-electronic.com
Manual for GENCON system’s Communicator Com2 Pro

Software version 1.21, Revision 1.72
Technical Data
• DC supply range: 8..40V

• DC supply load: 110mA (without a GPS)
• Battery capacity: 125mAh (Lithium coin cell 3V CR1632)
• Battery load: 25µA (during DC failure)
• Operating temperature range: -10°C..+60°C
When switched on these toggles introduce, from left to right:
1. 120Ω termination to the RS485 cable end.

2. Battery backup to maintain the data memory (RAM) and the real time clock (RTC) in the
absence of a DC supply. Keep this toggle switched off when the unit is in storage as the coin
battery would otherwise get discharged within about 6 months.
3. Software reset: Switch on (down) and then off (up) to restart the software.
• Use the provided serial cable (1:1 DB9M/DB9F) to connect a PC (DTE) via J1 or a
modem (DCE) via J2.
• J3 connects to an optional auxiliary I/O board such as the IOB1 for general purpose I/O
and IOB3 for remote annunciation.
• J4 connects to an optional GPS receiver. This PC-PS/2 like connector provides the GPS
receiver with power and NMEA RS232-TTL compatible serial communication lines. The
connector matches the plug of MR-350 from USGlobalSat (no cable-set is required).
Socket Description
1 GND
2 5V DC 80mA regulated output
3 12V DC regulated output (*)
4 TxD output
page 1 of 17
2
Tel: +49-2162-400 25, Fax: +49-2162-400 35
5 RxD input
6 GND
(*) GlobalSat began grounding pin 3 of their round MR-350 GPS connector (ouch, why?). As a
result, all the Communicator units from S/N B80H01016 have their 12V printed circuit board
(PCB) trace disconnected from terminal 3 (easy to restore if necessary). If you have an earlier
Communicator unit and you intend to connect it to a new MR-350 device please check carefully
if its pin 3 is grounded as it may blow your Communicator's 1A fuse on connection. Contact
Wexler for advice regarding the necessary 12V PCB trace cut.
• J5 is a detachable screw type connector.

DC supply can be taken from the engine battery as the internal voltage regulator of the
Communicator is both LOAD-DUMP and ENGINE-CRANKING protected.
INPUT [5] senses contact closing to the DC(-) potential. It is active when the contact to DC(-) is
closed.
The RS485 port is electrically isolated. It should be connected to the local area network (LAN)
like GENCON.
The firmware modbus.122 had been downloaded into the Communicator by your distributer. The
set-up.exe for Gpanes will be delivered to you on a CD together with the hardware. You MUST
install Gpanes on your PC’s hard disk running under Windows XP, normally under
C:\Program Files\gpanes. Whenever a new program is developped and you want to use the
improvements you must install that new programm again into your PC and download the
firmware into Comm2. That latter procedure is explained furtheron.
The normal procedure is to connect Comm2 with the Gencon(s) you want to control and with
your PC. The terminal block of Comm2 is clearly denominated on the front of Comm2. Both DC+
and both DC- are internally interlinked. The terminal 5 INPUT will be used only for downloading
firmware and is not used when Comm2 is employed exclusively for communication application.
The RS485 port of Comm2 must be connected with all Gencon(s) terminals B41 (+) and B42(-).
Connect the shield of a shielded communication cable to terminal 8 of Comm2 and to B43 of
Gencon when you are running a long distance between Comm2 and the generating sets where
the Gencons are controlling the application. You can connect all B41/B42 and B43 in parallel
within the general switchboard which will save you cable connection to Comm2. But make sure
that the terminal block used is protected against electromagnetic interference or put it at least far
enough from any relay. Otherwise run the cable from each genset to the communicator. Use an
adequate terminal block to connect them in parallel and from there to the terminal block of
Comm2 which for its size allows only one single wire.
On the right bottom edge of Comm2 you will find 3 dipswitches, normally all in OFF position. The
120Ω switch should be put into ON position if the communication cable is very long. The
BATTERY switch in ON position connects an internal back-up battery for the clock of Comm2.
Don’t put it in ON position when Comm2 is stored during a long time. The battery’s capacity
would run out within a few months. The dipswitch RESET is used only when Comm2 must
download firmware into itself or into a Gencon. We refer later to this procedure.
Connect now Comm2 Pro with your PC by the direct cable male/female which is part of the
supply. The female socket of Comm2 denominated J1 receives the male plug DB9 of the cable.
On the PC’s side, if there is no DB9 male socket and your PC provides exclusively USB ports
you must obtain in the market a conversion cable USB-SERIAL which ends in a USB plug on
one side and a male 9 pin plug on the other side. You may also use a PCI card as
communication port.
page 2 of 17
3
Tel: +49-2162-400 25, Fax: +49-2162-400 35
We assume now that all Gencons are powered up and connected to Comm2. Press key 7 on
each Gencon and control if the Network ID appears of that Gencon and of all others connected.
That will proof that your communication network is correct.
Now power up Comm2. The red LED will blink 4 times which shows that it is under the
communication option. Then is will change to a very fast blinking which proofes that a
communication between Comm2 and Gencon exists. Now go to the program file Gpanes in your
PC and click twice on the directory gpanes. A lot of files will apear. Ignore them all exept prog.
Click twice on it. Again some files appear. Ignore them all except the yellow button Gpanes.
Click again twice and a window opens. Now go to
TOOLS shown as two crossed screwdrives and click on it. Select “Find Comm” and let it search
the ComPort used by your PC. Memorize all data or write them down. Now click on the set-up
icon on top left of Gpanes window. Check that it has recorded correctly the COM port, COM
protocol, Speed Com, Parity and Flow. Ignore for the moment “Modem Select”. That is a
different chapter. SAVE the values before you exit Set-up. Go back to TOOLS and select Prog
Comm Modbus. The earlier data of the COM port must be programmed there. Modify only the
line “Last GENCON ID no.” which will determine the number of windows which will open, one
for every genset of the network. If you change the number of Gencon, you can scroll down or up
the numbers, select the number and then press OK at the bottom left hand. The new number of
Gencon will become valid as soon as you press the OK button. If you made a change you have
to restart the Communicator by its 3rd dipswitch called RESET. Put it into ON position and back
to OFF. The LED will blink again 4 times and then start to flash very fast. Now you are ready to
click on the button “Connect” (second on top). If you put the cursor of your mouse on each
button a text line will appear to explain what it is. Now a window will open, one for each
Gencon connected and denominated F1....F8. You can quickly activate any window by pressing
F1 or any F up to 8. But you can also select the window with your mouse. You can navigate
through each window exactly like you do it on Gencon, using the keyboard of your PC and right
and left mouse clic.
With your GENCON data correct in all windows you can choose now the red STOP button. Click
on it. If you have several Gencon check ALL. Then you may wish to program the time and day of
the week. Click on “Set Clock” and all Gencon will automatically take the information from your
PC clock, including the day. If you click now on “Save Gencon Config” the Communicator will
write all parameter textes and their values into a file which will be saved under the same
directory, for each Gencon called Gencon1 or whatever its number is. Do not touch any button
while the program is processing the data. It would interrupt the task. To this Notepad file you can
add comments, print it and keep it in your maintenance file for consulting it at any later date.
Under the same STOP icon you will find STOP and a RESET buttons which correspond to the
funtion each Gencon has by identical buttons. Nothing you can do anymore than select the life-
belt where you find DOC and ABOUT for your info.
If you find now that the windows are either too small (for one or two gensets only) or too big for 8
Gencons connected you can change the Font. You have to disconnect Gpane by pressing on
the disconnect button. Then you have access to the set-up menu. Gpanes can use fixed size
(monospaced) fonts only. Courier New which is available in all XP systems is such a font. A
more legible monospace font can be installed from
C:\Program Files\gpanes\docs\Andalemo.TTF. Go to your PC Config System and choose “add
fonts”. Then take it from you gpanes directory under docs. After changing the font you MUST
check SAVE in the set-up menu or the change would not become effective.
page 3 of 17
4
Tel: +49-2162-400 25, Fax: +49-2162-400 35
Running everything correct and smooth you may wish to create graphs of electrical values.
Disconnect Comm2 and open the Set-up menu by a mouse click. Select “Data Logging”. A new
window opens which has several factory set values. Don’t change anything for the moment but
check only the field “Lock”. A RRD file is created and when ready you can connect Comm2
again with all Gencons. SAVE the new option within the set-up menu. There is a red button
following the Stop button. Press on this red button and it will light up to show that recording of
the data is starting. The values recorded are memorized in your PC, i.e. you can consult
data only during the time your PC was connected to all Gencons through Comm2. After
some time you can click on GRAPH and select the value to be exposed as a graph within the
time you choose. Buit remember that the time choosen has to correspond to the time Comm2
was connected to the PC and the red button showed that recording was running.
GPS detection
Between TOOLS and LIFEBELT you find a button with a globe. Putting the cursor on it DETECT
appears. This option is provided to connect a GPS receiver to the plug of Comm2 called J4
GPS. The receiver to be used from GlobalSat is type MR-350 WAAS Enabled Water Proof GPS
(Code 142537 and scan number 1425370000008) with a cable set for either direct connection to
the PC or through Comm2 with a round plug which fits into the socket of Comm2. You can
obtain information from
es-info@expansys.com asking for that type of product and a distributer near to your site.
When correctly installed, the GPS receiver will give you the coordinates of your site including
height above sea level. Consult http://www.mapquest.com/maps/latlong.adp and introduce there
the coordinates in decimals, exactly as shown by the information of Comm2. For your further
interest: introducing the coordinates without a sign means they are positive and correspond to
North of the Equator and East of Greenwich. For example 53.15151 (North) and 11.03279
(East) correspond to the site of the author in North Germany. If you put a negative sign in front
of the latitutde you have a site south of the Equator while a negative sign in front of the longitud
corresponds to a site west of Greenwich. On the map, reducing the scale by scrolling down the
scale bar will bring you exactly to the site where your GPS is installed. It is possible that you are
not able to connect to the Internet when clicking from here on
http://www.mapquest.com/maps/latlong.adp Copy the address and paste it on your Internet
Explorer’s address line.
After disconnecting Comm2 you may find another submenu in set-up which is “Display Power”.
When clicking on it an additional small window opens which shows the total kW and total kVAr
of all gensets connected. Remember that you interrupt the logging data procedure each time
you disconnect Comm2. It is recommended to carefully set-up all options before finally
connecting Comm2 with the gensets and let the system log the data you may be interested of
having the corresponding chart. Only one chart creates a file which is saved under the program.
If you want to maintain it you have to give it a different name and then ask for another chart of
different data.
The set-up menu contains also an option called “Event logging”. Before the event logging facility
can be used visit the Set-up menu to define the set of individual text messages that each
GENCON is using (or select which default messages file applies). This step is necessary since
GENCON passes its event log to Gpanes in a numeric code whose text equivalent can be
altered to suit the application (e.g., using the Gpanes provided gen2txt and txt2gen utilities).
Note that a messages file is being released with every GENCON firmware update. You can pass
text alterations that you have made to the firmware automatically into its corresopnding
messages file using the Ntran utility. Also note that the messages file that Gpanes expects is the
gen2txt conversion (i.e., in human readable form) of the original firmware-like file (in hexdecimal
code). If the event logging mechanism is enabled a new events.log file is opened every day. Old
log file copies are time stamped and kept on disk for the prescribed number of days.
page 4 of 17
5
Tel: +49-2162-400 25, Fax: +49-2162-400 35
If the PC is connected to the Internet and the e-mail fields are properly completed a short email
message would be sent automatically when a shutdown fault is detected.
Software revision 1.72 can write events to a daily rotated log file, opening a new file every
midnight. Shutdown faults can be emailed too if the PC has access to a mail server. Use
Gpanes with the Communicator's modbus firmware V1.21 or later. The events.log file is
based on editable messages files. See Gpanes' built-in help for further info. Here is a log file
example:
Wed Dec 26 02:53 AM G2: ---- MAINTENANCE REQUIRED

Wed Dec 26 02:53 AM G1: ---- GENSET STARTS TO RUN
Wed Dec 26 02:53 AM G1: ---- GENSET GOES ON-LOAD
Wed Dec 26 02:53 AM G1: ---- LOW BATTERY VOLTAGE
Wed Dec 26 02:53 AM G1: WARN GENSET WARNING FAULT
Request: If Gpanes crashes/hangs/etc. please tell us what its revision number is and also email
to us the gpanes_stderr.log and gpanes_stdout.log files that you find in Gpanes' home directory,
typically C:\Program Files\Gpanes.
Use of Modbus
If you are intend to create your own modbus program, disconnect Comm2 and click on TOOLS.
Select there, like you did before when checking the COM Port settings, the submenu “Prog
Comm Modbus”. The details from “first Modbus device” until the end are important for your
modbus communication. You should be familiar with Modbus.
The details to create the program and to use the corresponding modbus access orders to obtain
the desired information from Gencon are given in the attachement to this manual.
This ends the part which corresponds to the communication system through Comm2Pro.
Using Comm2Pro for download firmware into Gencon
page 5 of 17
6
Tel: +49-2162-400 25, Fax: +49-2162-400 35
Disconnect Comm2 by the button Disconnect. Select under TOOLS the submenu TERMINAL
and check it. This is only to remind you that you have to restart Comm2 by putting its dispswitch
number 3 into OFF position and again into ON. While the LED flashes you have to activate
terminal number 5 several times with a small wire of NEG BAT which you take from any of
terminals 2 or 3. The result must be that the LED stays ON. Go again into TOOLS and uncheck
TERMINAL. Then go back to TOOLS and choose “Load Gencon firmware”. Now select the
firmware of Gencon to be loaded. It can be on a floppy disk, on your hard disk or an USB stick.
Click on that program and a window opens which informs you about the software version, the
first 3 HELP lines and the LCD type of the program. For Europe the LCD type is Europe. For
other countries it can be English or Japanes, Russian etc. If you do not choose the correct LCD
type some special characters may be corrupted. We explain later, how to change the LCD type.
Anyway, if you have downloaded the firmware from Wexler’s homepage the program is always
for English LCD type and must be converted if your Gencon is not labelled English on its rear
panel.
Before you answer now the dialog with YES (or SI on a Spanish PC, or Ja on a German PC)
you must disconnect the power from Gencon and put its 2 dipswitches into Flash/Prog position.
Then power up Gencon again and press the YES button on the screen. The green and yellow
LED of Gencon will start to flash and a dialog on the PC screen will tell you when the download
is completed. Switch off the power of Gencon again before you put the 2 dipswitches into RUN
mode again. Then power up Gencon and look at the display. If a software version loaded was of
a different version than the previous one you may have to press and hold the 0 key until the text
message of the normal software appears in the display of Gencon.
When you pretend to load software version 36 (3.6) into a Gencon which has installed software
version 35 (3.5) or any earlier version you must erase the Gencon parameters by “Erase
Gencon parameters” in TOOLS. The preparation is the same like for downloading software into
Gencon, i.e. pass through TERMINAL which only reminds you to reset Comm2 by its 3rd switch
and activate terminal 5 by various touches with NEG BAT. The LED stays on. Then uncheck
TERMINAL and go directly to TOOLS clicking on Erase Gencon parameters. Before you
answer any question by YES take the power off Gencon and put its switches into loading
position, then power it up and answer YES. If you have downloaded before any software you
can proceed with erasing the parameter inmmediately in a second step or even do it before you
load a new software. When ready, remember to take power off Gencon and put its switches into
normal RUN position. To bring back Comm2 to normal communication task reset it again and
observe that the LED flashes four (4) times, then flashing very fast if communicaton with
Gencon exists.
Download Comm2Pro firmware into Comm2

This is normally done by your distributer. But you should always have the latest version loaded
which is either supplied to you free of charge or you can get it from Wexler’s website. The
present version is modbus.122. The procedure of downloading a new version into Comm2 is the
following: With gpanes on your PC screen and NO connection to Gencon you select in TOOLS
again TERMINAL and check it to remind you that you have to reset Comm2 Pro like described
earlier, ie. move dipswitch 3 to OFF and then to ON position and while the LED is blinking
connect several time NEG BAt to terminal 5 until the LED stays ON. Uncheck TERMINAL and
select under TOOLS “Load Comm Firmware. Then select the program modbus.122 by double
click wherever you have filed it. A dialog opens which says that the firmware is loaded into
Comm2Pro and later another info tells you that the program veryfies the correct download. A
message appears then to remind you that Comm2 has to be restarted by dipswitch 3 (simply
OFF and ON) until the LED flashes quickly which indicates that it has communication with
Gencon. If there is no Gencon connected the LED will stay off.
page 6 of 17
7
Tel: +49-2162-400 25, Fax: +49-2162-400 35
How to check the correct LCD version of Gencon firmware

Neither Comm2 nor a Gencon is required to do the conversion.
Under the gpanes directory and under the file “prog” you will find a green icon called “gen2txt”.
Double click on it. It will require that you select from your PC the original software file, for
example e-240V50Hz.35v. A dialog opens which says “writing from firmware” which means that
the program creates a Notepad text file with identical name and puts it there where the orignal
software is located. Double click on that text file and the following may appear:
The present date and time with coding text. The file you have selected and where it is located on
your PC. The Version and the LCD type. The only thing you should change without having a lot
of experience is the LCD type. Look on the label which is on the rear panel of your Gencon.
There is an indication which LCD type is used. Compare it with the 4th line of the information
given below. In our case the information is LCD: 1 which corresponds to the European LCD
type. Overwrite 1 by either 0 or 2 or 3 if you have different LCD types in your Gencon. Then
simply save the txt file. Do not pretend to change any other text without having a lot of
experience to do so without maintaining exactly the delimeters indicated. It must be done by
Notepad which does not allow you to overwrite. If you don’t maintain the delimiters, in the
second step a notice will appear: “line 2 corrupted”, for example, and it will not allow you to
convert this txt file into a firmware file again. (The present document is written under Word and
allows thus overwriting the text).
Mon Feb 04 13:38:39 2008 -*- Mode: Text; Coding: utf-8; -*-
File: B:\240v50hz.35v
Ver: IOB1:E Ver35v Jan 08
LCD: 1 (0:Eng/Japanese, 1:Euro, 2:Eng/Hebrew, 3:Eng/Hebrew/Arabic/Russian)
┌───────────────────────────────────────────────────────────
─┐
│Edit text in overwrite mode. Stay within the delimiters (░).│
└───────────────────────────────────────────────────────────
─┘
(1, 1, 20)
░Contact: ??????????░
(2, 1, 20)
░Phone No: ??????????░
(3, 1, 4)
░1993░
(4, 1, 6)
░311794░
(5, 1, 2)
░←→░
(6, 4, 20)
░RESET ALL PARAMETERS░
Converting a txt file into a firmware file again
Go now back into your directory of gpanes and click on prog. Select the blue icon called
txt2gencon. Click on it and select the txt file you have created in the previous step. The program
will tell you that it creates a firmware file based on the text file. This new program (firmware) will
be then saved automatically at the same position. Now you dispose of a Gencon software which
corresponds to the LCD type of your Gencon. You can download it into Gencon as described
under chapter Download Comm2Pro firmware into Comm2
page 7 of 17
8
Tel: +49-2162-400 25, Fax: +49-2162-400 35
Gpanes hints on:

Versions
Tools
Navigation
Immediate Commands
Data Logging
Event Logging
Fonts
Help / About indicates the recommended firmware version of the Communicator and the revision
of Gpanes software itself.
Gpanes incorporates the following Tools:
Find Comm
Gpanes scans the PC serial ports, COM1..COM8, trying to determine on which port the
Communicator is installed and what Modbus communication parameters it is currently using.
Note that the PC serial port can be implemented through a PCI card or through a USB
converter. Use the Set-up / Save function to remember your found parameters for the next
activation of the program.
Find Modem
Gpanes can connect to a remote site also through a telephone modem. This utility helps you to
find on which serial port your PC modem is installed. When the modem is detected you can use
Tools / Terminal (see below) "to talk" directly with the modem. For example, you may be
interested to send an AT&F command to the modem in order to restore its set-up to the "safe
factory defaults".
Prog Comm Modbus
This programming sheet sets up the communication parameters. Though these parameters
immediately change the EEPROM memory you will need to restart the Communicator before
your changes take effect. You may wish to save this programming to a disk file. See the
following Tools / Save Comm Prog utility that operates in the bootloader mode.
Prog Comm Anna
This programming sheet sets up annunciation panel support that is available through the
Communicator's auxiliary 32-way IOB3 or 8-way IOB1 board.
Terminal
This is a simple terminal emulator which is mainly used "to talk" to the Communicator in its
bootloader mode. Before using the following load/save utilities that work in the "bootloader
mode" it is recommended to use this terminal to confirm that the Communicator has indeed
entered the bootloader mode.
Load Comm Firmware
Replace the Communicator software (firmware) using this tool.
Load Comm Parameters
Load Modbus and Annunciation Panel programming information from a disk file.
Save Comm Parameters
Save Modbus and Annunciation Panel programming information to a disk file.
Load Gencon Firmware
Like the other utilities in this group you have to begin by confirming through the Terminal that the
Communicator operates in its bootloader mode (this would not be necessary when you load
firmware to more GENCON units in sequence). Set GENCON's dip-switches to FLASH and
PROG mode, connect its RS485 port to the Communicator but switch GENCON up only when
Gpanes tells you so.
Erase Gencon Parameters
page 8 of 17
9
Tel: +49-2162-400 25, Fax: +49-2162-400 35
GENCON parameters are kept on a non-volatile EEPROM memory. Set GENCON's dip-
switches to the PROG mode, connect its RS485 port to the Communicator but switch GENCON
up only when Gpanes tells you so. Following erasure of the EEPROM Gencon would restore the
"factory default values" to all parameters the next time it powers up normally. Note that
calibration of the battery and the D/A would be lost -- you may wish to visit the FACTORY menu
prior to erasure in order to restore them later manually.
GENCON panes are mouse click sensitive, the left button sends Enter keys and the right button
sends Escapes. When a menu is displayed on screen the left button automatically invokes a
clicked menu function. The PC keyboard is supported as well.
The group of immediate commands can stop a genset or reset (accept) its pending faults. If the
All box is checked the clicked command applies to all the network controllers together. Set Clock
adjusts GENCON clocks based on your PC setting. Save Gencon Config, provided that you
know the password, automatically traverses most GENCON parameters and copies their
description and values into a (utf-8 encoded) text file. The text file can later be found in Gpanes
installation directory, for example: C:\Program Files\gpanes\gencon1_config.txt
Before data logging can be used visit the Set-up menu to define the round robin database
(RRD) parameters and to create its files (lock checkbox). The set-up parameters define the RRD
storage length and the frequency at which samples are recorded. The RRDtool charting facilities
require two true type fonts, DejaVuSansMono-Roman.ttf and VeraMono.ttf, which your PC may
not have. You can install these fonts from the C:\Program Files\gpanes\rrdtool subdirectory
using the menu function: Start → Control Panel → Fonts → File → Install New Font.
Before the event logging facility can be used visit the Set-up menu to define the set of individual
text messages that each GENCON is using using (or select which default messages file
applies). This step is necessary since GENCON passes its event log to Gpanes in a numeric
code whose text equivalent can be altered to suit the application (e.g., using the Gpanes
provided gen2txt and txt2gen utilities). Note that a messages file is being released with every
GENCON firmware update. You can pass text alterations that you have made to the firmware
automatically into its corresopnding messages file using the Ntran utility. Also note that the
messages file that Gpanes expects is the gen2txt conversion (i.e., in human readable form) of
the original firmware-like file (in hexdecimal code). If the event logging mechanism is enabled a
new events.log file is opened every day. Old log file copies are time stamped and kept on disk
for the prescribed number of days.
If the PC is connected to the Internet and the e-mail fields are properly completed a short email
message would be sent automatically when a shutdown fault is detected.
Gpanes can use fixed size (monospaced) fonts only. Courier New which is available in all XP
systems is such a font. A more legible monospace font can be installed from
C:\Program Files\gpanes\docs\Andalemo.TTF.
Attachement for Modbus

COMM2_PRO(modbus) Immediate replies to Modbus queries, read from the Communicator
memory, makes it easier to share a Modbus master serial port and cable with other Modbus
devices.
• The gen-set controllers refresh the Communicator memory (almost) simultaneously. In a

maximal 8 generator system a complete memory refresh of input statuses and registers would
take less than 3 seconds altogether
• Annunciation panel support through IOB3 or through IOB1, if only eight potential free
contacts are needed. The IOB3, if necessary, can also drive two 16 output independent
annunciation panels.
• Complete configuration through EEPROM based holding registers.
page 9 of 17
10
Tel: +49-2162-400 25, Fax: +49-2162-400 35
Modbus protocol configuration
The Communicator keeps its configuration parameters on a non volatile EEPROM memory,
accessible as Modbus holding registers. An erased EEPROM has all these registers set to -1
which corresponds to addressing the Communicator as device no. 9 with the Modbus ASCII
serial protocol using 7 bits, 19200 bps and even parity. Note that changing the protocol
configuration parameters would require a software restart. The protocol configuration is
conveniently changed through Gpanes Tools.
200ms is a safe Communicator response timeout which should be good also for long
Modbus transmissions. It is not recommended to rely on the timeout mechanism to detect
inaccessible GENCON controllers. Instead, the Communicator's input register 30005 can tell
which genset is free from a shutdown fault and which set is connected. Also, reading register
30005 is a way to reset the important watchdog timer mechanism.
The Communicator Modbus map

Coils:
If the annunciation panel is disabled (Anno = -1) coils 00001 to 00008 correspond to the 8
relays of the auxiliary IOB1 board, if one is installed.
Input status:
If the annunciation panel is disabled (Anno = -1) input statuses 10001 to 10016 correspond to
the 16 contact inputs of the auxiliary IOB1 board, if one is installed.
Holding registers:
The Communicator's holding registers can be written only one at a time, through function 06 or
through function 16 with a quantity of one.
• The following holding registers give access to the Communicator EEPROM kept
configuration:
Address Name Description

Annunciation panel, 4 registers per lamp (4x32 in
40001 Ann
total).
page 10 of 17
11
Tel: +49-2162-400 25, Fax: +49-2162-400 35
40129 LastID ID number of the last GENCON in use: -1/default (8)

40130 Anno Annunciation panel: -1/disable, 0/enable
Annunciation panel type: -1/single panel, 0/dual
40131 Apart (split) panel. Version 1.17: This feature was disabled,
only a single panel is available.
This bit-mask corresponds to outputs #1 to #16. It
determines which output upon activation (due to
triggering of one of its status terms) will turn on the
(audible-alarm) horn too. The horn is driven by
40132 Audible-1
output#32 (or output#16 if the annunciation panel is
split, see Apart is zero). For example, if this register
is hexadecimal FF7F output#8 will NOT activate the
horn.
This bit-mask corresponds to outputs #17 to #32. It
40133 Audible-2 determines which output upon activation would
activate the horn too.
Modbus protocol: -1/ASCII, 0/RTU. In dial-up modem
40134 Asc connections it is recommended to use the MODBUS
ASCII protocol.
40135 Baud RS232 bps: 0/9600, ±1/19200, 2/38400
40136 Parity RS232 parity: -1/even, 0/none, +1/odd, +2/8N1.
RS232 control: -1/none, 0/RTS RS485 direction,
40137 Flow
+1/CTS RS232 handshake
40138 Offset Device addresses: -1/1..9, n/n+1..n+9
40139 Endian Double register order: -1/little-endian, 0/big-endian
255 (-1) or 0..254: This is a safety mechanism which
disconnects inactive telephone modem callers if no
query to status registers 30003..30005 is received
within the allowed watchdog time interval. This
watchdog mechanism also exercises the
Communicator's DC power fail and recovery
40140 WatchdogReset
hardware what is expected to resolve cases where
the software gets stuck for any reason. If this register
is -1 (or 255), which is the erased EEPROM (default)
value, the watchdog mechanism is inactive. A 0..254
range corresponds to a 1..255 second watchdog
timer delay.
1..9: Number of rings after which the modem should
answer the phone. Enter -1 if the RS232 port has no
modem. The Secret register value must be written
within 60 seconds after modem connection or
otherwise the login fails. The modem is initialized
shortly after software restart by the
40141 Rings
ATE0V1&D0<0D> and ATS0=Rings<0D>
commands followed by any ATuser provided string.
During initialization, after sending each CR <0D>
character and waiting for the modem OK response,
the Communicator turns its LED on. Thus, if there is
a problem in initializing the modem you should be
page 11 of 17
12
Tel: +49-2162-400 25, Fax: +49-2162-400 35
able to detect it through the long LED turn on time.

Station ID. This is the only function 3 readable
40142 Station
register after modem connection and before login.
Modem login secret number. Use modbus function 6
40143 Secret
with this number to login.
User-defined modem initialization string. The string
ends with a NUL <00> or with any non ASCII
character. The character ~ introduces a 2 second
delay and is not sent to the modem. After sending a
CR <0D> to the modem further transmission halts for
40144 ... ATuser 1 second.
Example: To enable data answer mode in Qualcomm
based CDMA modems the following init string is
required: AT$QCVAD=4<0D>. Each register holds
two characters. In the example register 40144 holds
the hexadecimal number <5441>.
• If the annunciation panel is enabled (Anno = 0) each relay or lamp driver can indicate
the activity of upto four status terms. In the following example Hexadecimal numbers encode the
input statuses, the ID numbers begin from zero:
Register Status Term (code id) Description

40001 05 00 Relay K#1 of GENCON #1 is energized
40003 FF FF Unused
40004 FF FF Unused
40005 FF 00 No response from GENCON #1

40005 FF 01 No response from GENCON #2
40006 FF FF Unused
40007 FF FF Unused

40010 FF FF Unused
40011 FF FF Unused
• The Real Time Clock (RTC), if the battery switch is on, counts seconds also without a
DC supply. The RTC is accessible as two holding registers at addresses 40257 and 40258.
After software restart the clock begins counting from the largest negative integer (hexadecimal
80000000). The RTC can be preset through function 16.
Input registers:
• Input register 30001 displays the software version.

Input register 30002 is 1 if INPUT [5] is active and 0 otherwise.
page 12 of 17
13
Tel: +49-2162-400 25, Fax: +49-2162-400 35
• Input register 30003 returns the status of the LCD snapshots capture (each LCD
snapshot is available through registers 30080-30160 from the corresponding GENCON device).
The Communicator sends the reply back to the MODBUS master only when at least one new
LCD snapshot is available. Thus, querying this register before reading the snapshots (instead of
using a fixed delay loop) can lead to a faster display update on the MODBUS master (HMI)
screen. The response high-byte indicates which GENCON controller is connected to the RS485
LAN. The response low-byte indicates which GENCON has a new LCD snapshot in waiting. For
example, if the response is 0302 (hexadecimal) it means that there are two GENCON controllers
(G1 and G2) connected to the RS485 LAN but only G2 has a new LCD snapshot capture
waiting.
Querying input register 30004 would return the same reply (like querying 30003) only that the
reply would return immediately.
Input register 30005 returns bits set in the low byte whose bit position corresponds to controllers
with no pending shutdown faults. Bits set in the high byte correspond to switched on controllers.
It is recommended to query this register periodically together with the WatchdogTimerReset
protection.
• GPS receivers with SiRF chip-set can be read through input registers 300129 to 30155.
The navigation information is extracted from Output Message ID 2 of the SiRF binary protocol.
Address Name Description

30129 xpos X ECEF position, 32-bit unsigned integer
30131 ypos Y ECEF position, 32-bit unsigned integer
30133 zpos Z ECEF position, 32-bit unsigned integer
30135 xvel X ECEF velocity, 16-bit unsigned integer
30136 yvel Y ECEF velocity, 16-bit unsigned integer
30137 zvel Z ECEF velocity, 16-bit unsigned integer
30138 hdop HDOP, 16-bit unsigned integer
30139 mode LSB = MODE1 MSB = MODE2, 16-bit unsigned integer
30140 week GPS week 0..1023, 16-bit unsigned integer
30141 tow Time of week in 1/100s resolution, 32-bit unsigned integer
30143 nfix SVs in Fix, 16-bit unsigned integer
30144-55 prn 12 satellites PRN reports, 16-bit unsigned integers
Diagnostics
The response to a Return Query Data request (function 08, sun-function 0, 2 data bytes) is to
loopback the data with the bits inverted (1's complement). The stadard suggests to loopback the
same data but this is not useful as it would be no different than an echo.
GENCON Modbus map
GENCON device address is its {Controller ID No}, 1..8, unless an offset is added as may be
needed when sharing the serial communication cable with other Modbus devices (see the
Communicator holding register Offset).
Coils:
page 13 of 17
14
Tel: +49-2162-400 25, Fax: +49-2162-400 35
Coils are read through function 01 and written through functions 05 and 15. If GENCON runs the
standard software, coils 3-8 must be written twice with the same value for the new command to
be accepted. Also, the standard GENCON software requires these commands to be repeated
periodically (less than 25 sec apart) or otherwise GENCON raises the COMM2 TIMEOUT
ERROR alarm and cancels the test or run command. Note that this GENCON behavior can be
changed through the special software options #12 and #19. The recommended method for
KW/KVAR quota adjustment via the MODBUS protocol is through the pulsing method, where all
GENCON's {kW Quota++} .. {kVArQuota--} delays must be set to zero. Here is a snippet of a
Python program that was used to test this function 15 capability.
Coils
Address Description
00001 Reset faults (1 → press on GENCON's yellow button)
00002 Stop genset (1 → press on GENCON's red button)
00003 Test w/o load (1 → activate In#02)
00004 Run with load (1 → activate In#01)
00005 Increase kW export quota {In#00→ kW Quota++}
00006 Decrease kW export quota {In#00→ kW Quota--}
00007 Increase kVAr export quota {In#00→ kVAr Quota++}
00008 Decrease kVAr export quota {In#00→ kVAr Quota--}
Input status:
The following status map corresponds to the latest GENCON software version.
Input Statuses
Address Hex Description
10001 00 Relay R#1 (genset load control): 1/on, 0/off
10002 01 Relay R#2 (visual alarm or genset usable)
10003 02 Relay R#3 (audible alarm)
10004 03 The genset is: 1/master, 0/slave
10005 04 The genset is: 1/on-load, 0/off-load
10006 05 Relay K#1 (pre-glow)
10007 06 Relay K#2 (fuel solenoid)
10008 07 Relay K#3 (starter motor)
10009 08 Relay K#4 (air flap)
10010 09 Relay K#5 (lub. pump)
10011 0A Relay K#6 (engine running indicator)
10012 0B Relay K#7 (gen breaker)
10013 0C Relay K#8 (mains breaker)
10014 0D IOB error (MALFUNCT or NO COMM)
10015 0E RPM vs FREQ1 mismatch
10016 0F Gen phase order
page 14 of 17
15
Tel: +49-2162-400 25, Fax: +49-2162-400 35
10017 10 Gen overvoltage

10018 11 Gen undervoltage
10019 12 Gen over frequency
10020 13 Gen under frequency
10021 14 Gen overcurrent
10022 15 Gen reverse power
10023 16 Gen loss of excitation
10024 17 Gen over harmonics
10025 18 Battery over voltage fault
10026 19 Battery under voltage fault
10027 1A Emergency stop
10028 1B Low oil pressure shutdown
10029 1C Low oil pressure warning
10030 1D Hot water temp shutdown
10031 1E Hot water temp warning
10032 1F Low water temp warning
10033 20 Low water level alarm
10034 21 Low fuel level warning
10035 22 Battery charger warning
10036 23 Air damper closed
10037 24 Not in auto mode warning
10038 25 External overload
10039 26 Configs #1-6: Contactor failure, Config #0: Generic Config Error
10040 27 Mains contactor fails to close
10041 28 Override shutdown faults
10042 29 Overspeed
10043 2A Synchronizer timeout
10044 2B Network rs-485 error
10045 2C Unexpected bus volts shutdown
10046 2D Immediate shutdown
10047 2E Delayed shutdown (engine stops after cooling off)
10048 2F Cumulative warning
10049 30 Cumulative warning or shutdown
10050 31 Current measurement error
10051 32 Engine over-crank
10052 33 Engine slow-crank
10053 34 Starting failure (didn't build volts, freq or oil pressure)
10054 35 Stopping failure
10055 36 IOB2 sender#1: low ohms (e.g., high temperature)
page 15 of 17
16
Tel: +49-2162-400 25, Fax: +49-2162-400 35
10056 37 IOB2 sender#2: low ohms

10059 3A IOB2 sender#1: high ohms
10060 3B IOB2 sender#2: high ohms
10061 3C IOB2 sender#3: high ohms
10062 3D IOB2 sender#4: high ohms
10063 3E IOB2 sender#1: open circuit
10064 3F IOB2 sender#2: open circuit
10065 40 IOB2 sender#3: open circuit
10066 41 IOB2 sender#4: open circuit
10067 42 AVR control failure
10068 43 Governor control failure
10069 44 COMM2 timeout error
10070 45 Auto mode indicator
10071 46 In#15, Gen breaker aux contact
10072 47 In#16, Mains breaker aux contact
10073 48 Maintenance required (running-hours or service-weeks)
Holding registers:
GENCON has a single holding register, 40001. This register gives access to the keypad. If
GENCON is busy with a previous key entry the Communicator would return a SLAVE DEVlCE
BUSY (6) exception. The acceptable hexadecimal-codes are: Return/0D, Escape/1B, Left/25,
Up/26, Right/27, Down/28, 0/30, 1/31, 2/32, 3/33, 4/34, 5/35, 6/36, 7/37, 8/38, 9/39.
Input registers:
Most GENCON analog readings are represented by two consecutive input registers in IEEE 754
floating point format.
Input Registers
Address Description
30001 KWH count, Unsigned 32-bit integer
30003 Engine run-time hours count, Unsigned 32-bit integer
30005 Sender 1, Floating point (e.g., °C or °F)
30007 Sender 2, Floating point
Active load-share, Signed 16-bit integer
30013 +8192 represents 100% engine (KW) load
-32768 indicates that the genset is not a master
Reactive load-share, Signed 16-bit integer
30014
+8192 represents 100% generator (KVA) load
page 16 of 17
17
Tel: +49-2162-400 25, Fax: +49-2162-400 35
-32768 indicates that the genset is not a master

30015 V1 Volts (gen phase A), Floating point
30017 V2 Volts (gen phase B), Floating point
30019 V3 Volts (gen phase C), Floating point
30021 I1 Amps (gen phase A), Floating point
30023 I2 Amps (gen phase B), Floating point
30025 I3 Amps (gen phase C), Floating point
30027 V1 Hz (gen frequency), Floating point
30029 Gen Total KW (active power), Floating point
30031 Gen Total KVAR (reactive power), Floating point
30033 Gen Total KVA (apparent power), Floating point
30035 V4 Volts (bus phase A), Floating point
30037 V4 Hz (bus frequency), Floating point
30039 Battery Volts, Floating point
30041 Engine RPM, Unsigned 16-bit integer
Registers 30070 to 30073 return a snapshot of GENCON's last eight events. Each register
packs two events where the latest event code enters register 30070's high byte and the oldest
event is pushed off from register 30073 low byte. 0 code stands for an empty event log entry.
The messages that are asociated with each event code can be obtained from GENCON's
firmware file using Gpanes' gen2txt utility: 1 stands for GENCON UP: SET CLOCK; 2 for
GENCON LOW DC DANGER, etc.
Register 30080 low byte passes the LCD cursor position: 0..79 if the LCD cursor is blinking or
255 if the cursor is switched off. The high byte of this register passes the following boolean
indicators (from msb to lsb): ON-LOAD, MASTER, 0, 0, 0, WARNING, SHUTDOWN, RUNNING.
Registers 30081 to 30160 pass the LCD contents in 16 bit Unicode format known as UCS-2.
page 17 of 17

Info@dsl-Electronic - de WWW - Dsl-Electronic - de

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Info@dsl-Electronic - de WWW - Dsl-Electronic - de

Uploaded by

Copyright:

Available Formats

1

DSL-electronic® GmbH , Schiricksweg 2, D 41751 Viersen

Manual for GENCON system’s Communicator Com2 Pro

• DC supply range: 8..40V

When switched on these toggles introduce, from left to right:

1. 120Ω termination to the RS485 cable end.

• J5 is a detachable screw type connector.

Wed Dec 26 02:53 AM G2: ---- MAINTENANCE REQUIRED

Using Comm2Pro for download firmware into Gencon

Download Comm2Pro firmware into Comm2

How to check the correct LCD version of Gencon firmware

Converting a txt file into a firmware file again

Gpanes hints on:

Attachement for Modbus

• The gen-set controllers refresh the Communicator memory (almost) simultaneously. In a

Modbus protocol configuration

The Communicator Modbus map

Address Name Description

40129 LastID ID number of the last GENCON in use: -1/default (8)

able to detect it through the long LED turn on time.

Register Status Term (code id) Description

40005 FF 00 No response from GENCON #1

40008 05 00 Relay K#1 of GENCON #1 is energized

• Input register 30001 displays the software version.

Address Name Description

GENCON Modbus map

10017 10 Gen overvoltage

10056 37 IOB2 sender#2: low ohms

-32768 indicates that the genset is not a master

You might also like