PL1000E Quick Reference Guide{7610} Caterpillar

Electric Power Generation: All

Engine:Industrial, Marine, and Generator Set that Use Flash Programming All

Introduction

This Special Instruction is intended to be used as a quick reference guide for the PL1000E. This Special Instruction provides instructions to configure the software that is required to interface a PL1000E with a "Programmable Logic Controller" (PLC) for the first time.

This Special Instruction includes information for the process to create a .pcl file, configure the PL1000E, and how to install the .pcl file onto the PL1000E.

If needed, refer to the Systems Operation Troubleshooting Testing and Adjusting Manual, RENR8091 or Special Instruction, REHS2362 for more detailed information.

Before the PL1000E can be configured, the following list of information must be gathered.

1. Verify that the PLC supports native Modbus v1.1a, NOT Modbus+.

2. Verify that the PLC is a Modbus Master that is capable of requesting registers 40,001 through 42,000.

3. Determine the protocol that is required for the Modbus communications. ("Transmission Control Protocol" (TCP), RS-232, RS-485 (4 wire), RS-485 (2 wire), and RS-422).

4. Determine the baud rate that is required for the data link.

5. Obtain the Modbus slave address that the PLC will use in order to request the information from the PL1000E.

6. If connecting to a network, gather the following information.

   Note: "Dynamic Host Configuration Protocol" (DHCP) addressing will auto configure on a dynamic network. "Static" addressing will need to be configured manually. "Static" addressing will require:

   • Internet Protocol (IP) address

   • Subnet address

   • Gateway address

7. Determine the datalink address of engine ECM, whether Cat Datalink (CDL) or J1939.

8. Determine if there are any accessories that are connected to the system. Determine the datalink address of the accessories. Two examples of accessories that might be connected to the system that uses an EMCP 3 control is a "Integrated Combustion Sensing Module" (ICSM) or an "Integrated Temperature Sensing Module" (ITSM).

9. Decide which available parameters from the engine ECM, or other Caterpillar ECMs, will need to be monitored.

Determine the Datalink Address

In order to retrieve data from each ECM that is connected to the PL1000E, the data link address of each ECM must be known. The data link address is required in order to create the .pcl file.

Caterpillar Electronic Technician (Cat ET) or Caterpillar Communications Tool Kit ( Cat CTK) must be connected to each component individually in order to determine the data link address.

Determine whether the "Embedded Communications Adapter" (ECA) is being used or if the "Communications Adapter II (CA2)" is being used.

1. After the type of commnuications adapter has been identified, click "Utilities", then click "Preferences" in order to access the "Preferences" dialog. The "Preferences" dialog will display the type of adapter, either the ECA (1) or the CA2 (2), that is being used. Refer to Illustration 1.

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Illustration 1	g01470882

Note: The communications (COM) port may also need to be configured in order to match the active com port of the computer.

2. Click "OK" (3) after the desired changes have been made in order to apply the changes.

3. Click the "Connect" icon that is located at the top of the application dialog or press the "F8" key.

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Illustration 2	g01471012
Connect Icon

4. If there is more that one ECM that is connected to the Cat Datalink (CDL) or to the J1939 "Control Area Network" (CAN), select each ECM one by one in order to determine the address of the ECM.

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Illustration 3	g01471034

5. Click "OK".

6. Once Cat ET software has connected to an ECM, press "CTRL+I". A system information dialog will appear. The system information dialog will display the ECMs that are detected.

7. Click on the desired ECM. The "System Information" dialog for the specific ECM will appear. Refer to Illustration 4.

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Illustration 4	g01471055

8. The Datalink address is based on the "Real Device ID" value. Refer to Illustration 4.

   1. Use the first two digits from the real device id. In this example, the value is "21".

   2. The value "21" is in hexadecimal format.

   3. The hexadecimal value "21" must be converted to a decimal number. Therefore, the hexadecimal value "21" equals "33" in the decimal system.

   4. Therefore, "33" is the address of the CDL ECM object that is in the .pcl file.

Creating a .pcl File

A "Parameter Configuration List" (.pcl) file is required. The .pcl file informs the PL1000E which ECMs to communicate with and which parameters are to be made available over Modbus.

1. Click the "Utilities" option (4) that is displayed on the menu bar of the Cat ET dialog. The Cat ET connect dialog will appear.

   Note: Connection to the PL1000E is not necessary in order to use the .pte editor, click "Stop Connect" (5) .

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Illustration 5	g01471092

2. The Cat ET .pte dialog will appear. From the "Options" menu (7), click "New" (8), then click "Modbus Slave" (9) .

   This publication assumes that the PLC is a "Modbus Master" that is capable of requesting registers 40,0001 through 42,000. This publication assumes that the PL1000E will provide the response as a "Modbus Slave".

   For information to configure the PL1000E as a "Modbus Master", refer to the Systems Operation Troubleshooting Testing and Adjusting Manual, RENR8091.

Illustration 6	g01471112

Add a Modbus ECM

1. At the Cat ET .pte dialog, go to the "Object Type" field (13) in order to add a Modbus ECM.

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Illustration 7	g01471152

2. Click on the oval (14) that has a green plus sign.

   Note: If desired, the "New Modbus ECM" object can be renamed to some other preferred name. In order to change the name, click the "New Modbus ECM" object, then type the preferred name in the description column. Refer to Illustration 8 and Illustration 9.

Illustration 8	g01473293

Select a New Modbus Object and Configure a New Modbus Object

1. Click the "New Modbus ECM" object in order to select the object. After the object has been selected, then the object can be configured. The object represents the output of the PL1000E. The ECM ID (15) must be unique for every ECM object. The slave address (16) is the number that will be used by the polling system in order to request information from the PL1000E.

Illustration 9	g01471173

Add a New CDL, J1939 or Webserver ECM Object

1. A new CDL, J1939 or webserver ECM object will need to be associated with the appropriate .pte file (18). Some applications will require more than one ECM object. An example of this application are engines that use multiple ECM objects such as a ITSM or a ICSM.

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Illustration 10	g01471192

Note: Refer to Illustration 11. The directory path (19) is where the .pte files are stored. The directory path is user selectable.

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Illustration 11	g01492135

2. Click the "New" CDL object (21) in order to configure the object. Be sure that each ECM ID (22) and the address for every ECM object (23) is unique. The CDL or J1939 address must match the engine or the accessory ECM data link address, the "Module Identifier" (MID). Refer to Illustration 12 and Illustration 13.

   Note: The address information can be found through Cat ET or Cat CTK. Press "CTRL + I" while the computer is connected to each component or follow the instructions that are provided in the component specific literature.

Illustration 12	g01471218

Illustration 13	g01471219

Add Translation Lines

1. The translation lines (26) are used in order to defined the parameters. Translation lines usually flow from the CDL, the J1939 or the Webserver to the Modbus. The translation lines inform the PL1000E what parameters are to be translated to the Modbus protocol.

   Translation lines can flow from the Modbus object to the CDL object of the engine ECM. The configuration will allow for some controls to be done remotely.

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Illustration 14	g01471221

2. Click on one of the translation lines. The translation line will become hightlighted in red. A list of parameters that can be chosen will appear on the right hand side of the dialog. Select only the parameters that are desired. Refer to Illustration 15.

   Note: An excessive amount of parameters may overload the CDL communications traffic.

Illustration 15	g01471222
Example of a Parameter List

Save the .pcl File

1. Save the .pcl file after the ECM objects are configured and after the parameters have been chosen. The file that is to be saved will be the file that is loaded onto the PL1000E.

2. Go to the "Options" menu (27) in the dialog. Click "Save" (28) .

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Illustration 16	g01471224

3. Once the file has been saved, click on a translation line (26). The parameter list dialog (30) for the translation line will appear on the right hand side of the .pte dialog.

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Illustration 17	g01474713
(26) Translation Line (30) Parameter List (31) View/Save Parameter List Report Icon (32) Reassign Modbus Registers Icon (33) Select All Parameters Icon

4. Click the "View/Save Parameter List Report" icon (31). The parameter list report will appear. Refer to Illustration 18.

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Illustration 18	g01471226

5. Click "Save to file". The "Save to file" command will create an Excel file. The Excel file will contain necessary information that is useful for the process to configure the communication between the PLC and the PL1000E.

6. The process that is discussed in this section must be repeated for each translation line.

Configure the PL1000E

1. If multiple ECMs are on the Cat Datalink (CDL) or J1939, then click on the PL1000E (36). Click "OK" (37).

   Note: By default, the PL1000E is set to " #2". The ECM "Module Identifier" (MID) number can be changed in the configuration menu.

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Illustration 19	g01471232

2. After the laptop has connected to the PL1000E, then click the "Configure" icon (38) or press the F5 key.

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Illustration 20	g01471255

3. Click "Expand All" (39) that is located at the bottom of the dialog.

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Illustration 21	g01471273

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Illustration 22	g01515198
After the Dialog is Expanded, the Configuration Information will be show.

4. If the network uses DHCP, then ensure the DHCP setting is "enabled". If the network uses "Static" network addressing, then ensure that DHCP is disabled (40) before entering the IP address. Refer to Illustration 23.

   Note: Illustration 23 shows an example IP address.

   Note: If needed, then contact the network administrator in order to obtain the correct IP address.

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Illustration 23	g01471276

5. Determine which serial port is required in order to integrate the PL1000E to the PLC. Ensure that the baud rates match the PLC.

   Note: If the Modbus TCP is used, then the Modbus port selections do not need to be configured.

   Note: "Echo" (43), "Data Size" (44), and "Parity" (45) are for reference only.

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Illustration 24	g01471334

6. Each port can be configured as necessary. Click on a "Modbus Port Selection" (42). Refer to Illustration 24. The "Change Parameter Value" dialog will appear for that specific port. Refer to Illustration 25.

   The serial ports are configured as follows:

   • Serial port 1 is RS232

   • Serial port 2 is RS232

   • Serial port 4 is RS422 and RS485

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Illustration 25	g01471336

Note: Serial port 3 is not available for Modbus because the port is permanently configured as the "Embedded Comm Adapter" (ECA).

Note: Be sure to leave the "Modbus Datalink Addresses" at default 254 or 255.

7. The RS485 is defaulted to the 4 wire (full duplex) configuration. If the RS484 2 wire (half duplex) configuration is desired, then the .pcl file will have to be installed first. After the .pcl file has been installed, then the changes must be made on the configuration screen in order to select 2 wire. Refer to Illustration 26.

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Illustration 26	g01471340

Note: Only PL1000 hardware that is stamped with 285-1138 are able to utilize the 2 wire configuration.

8. The power to the PL1000E must be cycled in order for the settings to be applied.

Load the .pcl File onto the PL1000E

1. The computer must be configured in order to connect to the PL1000E over Ethernet. Click on the "Start" button (46). Then select "Control Panel" (47).

   Note: The following instructions use "Windows XP^tm". Even if other Windows based operating systems are used, the same, or similar, instructions can be used in order to perform the process to load the .pcl file.

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Illustration 27	g01471342

2. After the "Control Panel" dialog has appeared, click the "Internet Options" icon (48) .

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Illustration 28	g01471345

3. The "Internet Properties" dialog will appear.
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   Illustration 29	g01471348

   1. Click the "Connections" tab (49). Then click the "LAN Settings" button (50) .
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   Illustration 30	g01471349

   2. Ensure that the box for the "Automatically detect settings" (51) and the box for the "Use automatic configuration script" (52) are not checked.
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   Illustration 31	g01471351

   3. Click "OK" in order to apply the changes. Return to the "Control Panel" dialog.

4. Set up the network address for the computer for static IP addressing. If DHCP addressing is used on the network, then open Cat ET or CTK in order to determine the PL1000E's IP address and then proceed to Step 5.

   1. In the "Control Panel" dialog, click the "Network Connections" (55) icon.
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   Illustration 32	g01516836

   2. Click Local Area Connection (57) .
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   Illustration 33	g01516952

   3. In the Local Area Connection Status window click "Properties" (58).
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   Illustration 34	g01516958

   4. In the field that is titled "This connection uses the following items:", use the scroll bar to scroll down in order to locate "Internet Protocol (TCP/IP)". Double click "Internet Protocol (TCP/IP)" (59).
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   Illustration 35	g01475956

   5. The "Internet Protocol (TCP/IP) Properties" dialog will appear. Click "Use the Following IP address" (60) .

   6. Enter in the IP address (61) that was used for the PL1000E, except for the last set of numbers that are on the right end of the address. The last set of numbers that are on the right end of the address must be different than the PL1000E.

      Note: An example address for the PL1000E is "192.168.10.10". A typical subnet (62) for both the PL1000E and the PC is "255.255.255.0". The PL1000E address and the PC's defualt gateway need to match. An example default gateway is "1.0.0.0".

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   Illustration 36	g01471389
   Internet Protocol (TCP/IP) Properties Dialog

   7. After the required information has been entered, then click "OK" (63). Return to the "Control Panel" dialog.

5. Open Internet Explorer. Type the IP address that has been set for the PL1000E in the "Address" bar (65) .

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Illustration 37	g01471392

6. A dialog will appear asking if the user has permission to access the folder and to ask the user to log on. Press "OK". Refer to Illustration 38.

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Illustration 38	g01471393

7. A dialog, for the address that was typed, will appear. Click "File" that is on the tool bar.

8. From the drop down menu, click "Login As".

   Note: The default user name is "admin". The default password is "admin".

9. Double click the "New" file folder (66) .

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Illustration 39	g01471395

10. Drag the .pcl file, that was created, into the "New" file folder.

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Illustration 40	g01471396

11. Cycle the power to the PL1000E. After the power has been applied to the PL1000E, click "View", then click "Refresh". The .pcl file should disappear.

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Illustration 41	g01471397

12. Click the "Back" button (67), then click the "Current" folder. The file should appear in the "Current" folder. The screen may need to be updated. Click the "Refresh" button.

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Illustration 42	g01471398

13. The .pcl file is now loaded onto the PL1000E. Click the "Back" button.

Verify Communications

The following procedure can be used in order to confirm that the .pcl file has been properly loaded and to confirm that the hardware configuration is correct.

1. Change the FTP to HTTP (68) in the "Address" bar in order to enter the embedded web browser.

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Illustration 43	g01471413

2. Click "Status" (70) .

3. Click "ECM Mapping" (71). The "ECM Mapping" dialog will appear. If the file has been loaded correctly and if the ports are configured correctly to match the .pcl file, then there will no red writing on this page. Refer to Illustration 44.

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Illustration 44	g01471414

4. Click "Statistics" (72) in order to view the port activity. The "Statistics" screen shows an example of proper port activity.

   Note: If the port activity is operating properly, then the "Bytes Transmitted" and the "Bytes Received" will increment for the configured and for the active ports. Refer to Illustration 45.

Illustration 45	g01471415

Summary

If needed, refer to the latest revision of Systems Operation, Testing and Adjusting, and Troubleshooting, RENR8091 and Special Instruction, REHS2362 for detailed information.