Installation of the JBUS/MODBUS Communication Card{4480} Caterpillar

Installation of the JBUS/MODBUS Communication Card{4480}

Usage:

Uninterruptible Power Supply:: UPSB125 (S/N: SEP1-UP); UPSB130 (S/N: XTC1-UP); UPSB220 (S/N: JFA1-UP)

Introduction

This publication describes the installation of the 347-8485 Circuit Board As ( COMMUNICATION, JBUS, MODBUS) .

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this publication.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged. Ensure that the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures that are used.

Parts List

Show/hide table

Table 1
Part Number	Description	Quantity
347-8485	Circuit Board As (COMMUNICATION, JBUS, MODBUS)	1

Overview

Show/hide table




Illustration 1	g01995234
(1) Switches for RS485 settings (SA2) (2) Switches for JBUS/MODBUS settings (SA1) (3) RS232 link configuration jumpers (4) RS485 communication port (5) RS232 communication port (6) Diagnostic LED (7) Push button to restart the card

Functions

The 347-8485 Circuit Board As ( COMMUNICATION, JBUS, MODBUS) provides UPS (Uninterruptible Power Supply) data (states and measures) to be sent to a computer system. The JBUS hexadecimal (MODBUS RTU) communication protocol is used in slave mode. The system provides a communication channel with an RS485 or RS232 interface.

Note: The 347-8485 Circuit Board As ( COMMUNICATION, JBUS, MODBUS) may be used in all UPSs equipped with UPS BUS communication slots. Two wire or four wire RS485 links are available.

Note: RS232 and RS485 communication ports cannot be used together. JBUS/MODBUS communication is operational 2 minutes after the start-up of the card.

Technical Characteristics

Show/hide table

Table 2
Functions	Parameters	Default Values	Possible Values
JBUS/MODBUS communication	Baud Rate Parity Slave Number	1200 Bauds without parity Slave nr 1	1200, 2400, 4800, 9600 Without parity, even parity 1 to FF (hexadecimal)
RS232 link	Link connection in transmit data (Tx) or receive data (Rx)	Rx on pin 3 Tx on pin 2	Rx on pin 3 or pin 2 Tx on pin 2 or pin 3
RS485 link	Polarity Termination	No polarity No termination	With or without (two or four wires) With or without (two or four wires)

Note: The JBUS/MODBUS communication format is eight data bits and one stop bit. The JBUS/MODBUS communication format cannot be configured.

JBUS Protocol

The standard JBUS/MODBUS functions that are provided by the card are:

function 3: read n words
function 5: write 1 bit
function 6: write 1 word
function 16: write n words

The data (states or measures) are stored in a sequential way in the JBUS/MODBUS tables. In order to optimize the time to read the data, access blocks of words to decrease the number of the JBUS/MODBUS requests.

Installation

Configuration of the JBUS/MODBUS Communication Parameters

If needed, modify the default values of the JBUS/MODBUS communication parameters. Use the following steps that are listed below.

Show/hide table




Illustration 2	g01995933

Place all the "SA1" switches to the ON position.

Show/hide table




Illustration 3	g01995934

Connect the RS232 link to a terminal (Microsoft Hyper terminal).

Set the terminal with the following communication parameters:
- 9600 baud rate
- even parity
- one stop bit and seven data bits

Press the push button (7) on the card for more than 3 seconds.
Configuration mode is operational. Verify that the diagnostic LED (6) is blinking twice per second. The command prompt "CDE->" is displayed on the terminal screen.

Enter the configuration command that you require. Press the "Enter" key after each command is entered. Refer to Table 3.

When the required configuration is done, restart the board by pressing the push button (7) for less than 3 seconds.
The card will return to operational mode, and the new JBUS/MODBUS parameters are up and running after 2 minutes.

Show/hide table

Table 3
Command	Function	Value to Set
L	Reading current parameters	None
V	Baud rate setting	1200, 2400, 4800, 9600
P	Parity setting	0 (without parity) or 2 (even parity)
E	Slave number setting	from 1 to FF (hexadecimal)
M	Switching to echo mode	None

Note: The updated parameters are saved even if the card is turned off.

Note: In "eco" mode, characters that are typed into the keyboard are displayed on the screen. This mode is available only during the configuration of the communication parameters.

Note: The communication parameters for the terminal are not configurable and not related to the JBUS/MODBUS communication parameters.

Return to the Default JBUS/MODBUS Parameters

In order to return to the default parameters of the JBUS/MODBUS communication, perform the following steps:

Place all the "SA1" switches to the OFF position.

Press the push button (7) on the card for more than 3 seconds.

Show/hide table




Illustration 4	g01996076

Release the button (7) and restart the board by pressing the push button for less than 3 seconds.
The card returns to the operational mode and the default JBUS/MODBUS parameters are up and running after 2 minutes.

RS232 Link Configuration and Connection

Show/hide table




Illustration 5	g01996077

Show/hide table




Illustration 6	g01996078

RS485 Link Configuration and Connection

For proper operation, the polarity of the EIA RS485 2-wire and 4-wire lines must be set at only one point. The lines must be terminated at the end.

Polarity

Normally, the administrator of the network sets the polarity of the line (Rp resistor).

Termination

The two ends of the line must be terminated (Ra resistor). Allow for one or two terminators in order to avoid mismatching the line when any equipment at the end of the line is disconnected.

The default setting of the RS485 is a four wire configuration without polarity and without termination.

Show/hide table




Illustration 7	g02007276

SA2 switches are used in order to make the termination and the polarity of the RS485 link:

Polarity Resistance = 332 Ω

Termination Resistance = 166 Ω

1 - Polarity T- (J4-5) to + 5V

2 - Polarity T+ (J4-9) to 0V

3 - Link Termination T+ T-

4 - Connection T- to R- (J4-5 to J4-4)

5 - Connection T+ to R+ (J4-9 to J4-8)

6 - Polarity R- (J4-4) to + 5V

7 - Polarity R+ (J4-6) to 0V

8 - Link Termination R+ R-

Show/hide table




Illustration 8	g02007335

Diagram of a 2-Wire Inter-Cubicle Connection

Show/hide table




Illustration 9	g02007410

Card Settings of an Intermediate Cubicle in 2-Wire Connections

Show/hide table




Illustration 10	g02007453
Link without polarity and without termination

Card Settings of an End of Line Cubicle in 2-Wire Connections

Show/hide table




Illustration 11	g02008273
Link without polarity and with termination

Other Settings in 2-Wire Connections

Show/hide table




Illustration 12	g02008336
Link with polarity and termination

Show/hide table




Illustration 13	g02008339
Link with polarity and without termination

Diagram of a 4-Wire Inter-Cubicle Connection

Show/hide table




Illustration 14	g02008596

Card Settings of an Intermediate Cubicle in 4-Wire Connections

Show/hide table




Illustration 15	g02008754

Card Settings of an End of Line Cubicle in 4-Wire Connections

Show/hide table




Illustration 16	g02008756

Other Settings in 4-Wire Connections

Show/hide table




Illustration 17	g02008758

Show/hide table




Illustration 18	g02008759

Installation of the Card

Note: There is no need to turn the UPS or the STS off to change the card.

Remove the cover from a free slot in the UPS.

Insert the communication card into the UPS. Secure the card.

Once the card has been inserted and connected, the diagnostic LED (6) :

flashes regularly once per second during the start-up phase,
flashes faster during initialization of the dialogue with the UPS,
flashes in step with the exchange of data with the UPS.

Approximately 2 minutes after insertion, the JBUS/MODBUS communication is operational.

The 347-8485 Circuit Board As ( COMMUNICATION, JBUS, MODBUS) can be inserted in all products equipped with communication slots. For each of these products, data available through the JBUS/MODBUS protocol is listed in the tables that follow.

Operation

Status Table for UPSB125 and UPSB130

Show/hide table

Table 4
Status Description	Status to 0	Status to 1	Word JBus (Hex)	Word Modbus (decimal)	JBus Bit	Modbus Bit
Load protected	no	yes	40	65	0	1
UPS coupled	no	yes	40	65	1	2
Unit general alarm	no	yes	40	65	2	3
System downgraded operation	no	yes	40	65	3	4
UPS in backup	no	yes	40	65	4	5
Battery low warning	no	yes	40	65	5	6
End of backup time (voltage or time)	no	yes	40	65	6	7
Operation on static switch	no	yes	40	65	7	8
Emergency stop	no	yes	40	65	B	12
UPS in "on-line" mode	no	yes	41	66	1	2
UPS in "eco" mode	no	yes	41	66	2	3
Unitary/parallel-connected UPS	no	yes	41	66	3	4
Manual bypass switch (Q3BP)	open	closed	41	66	6	7
Battery end of life	no	yes	42	67	1	2
Battery test result	battery test OK	battery test error	42	67	2	3
Battery automatic test in progress	no test in progress	test sequence activated	42	67	8	9
Battery temperature out of tolerance	no	yes	42	67	A	11
Battery circuit-breaker (QF1)	open	closed	42	67	F	16
Rectifier normal on/off	rectifier off	rectifier on	44	69	2	3
Mains 1 input switch (Q1)	closed	open	44	69	3	4
Mains 1 voltage out of tolerance	no	yes	44	69	8	9
Mains 1 frequency out of tolerance	no	yes	44	69	B	12
Rectifier thermal overload	no	yes	44	69	C	13
Maintenance position	no	yes	46	71	1	2
Mains 2 overload	no	yes	46	71	5	6
Mains 2 thermal overload	no	yes	46	71	6	7
Mains 2 frequency out of tolerance	no	yes	46	71	9	10
Mains 2 voltage out of tolerance	no	yes	46	71	A	11
Phase M2 out of tolerance	no	yes	46	71	B	12
Mains 2 input switch (Q4S)	closed	open	46	71	E	15
Forced desynchronization	no	yes	47	72	1	2
Output switch (Q5N)	closed	open	47	72	B	12
Number of UPS ready sufficient for coupling	no	yes	47	72	F	16
Charger general fault	no	yes	49	74	0	1
Battery charged state	not in charge	in charge	49	74	3	4
Major UPS fault	no	yes	4C	77	1	2
Inverter overload	no	yes	4C	77	2	3
Inverter thermal overload	no	yes	4C	77	3	4
Inverter limitation	no	yes	4C	77	4	5
Output thermal overload	no	yes	4C	77	5	6
Output overload	no	yes	4D	78	F	16
Inverter fuse fault	no	yes	4F	80	0	1
Output in short-circuit	no	yes	4F	80	1	2
End of warranty soon	no	yes	43	68	1	2
Technical check recommended	no	yes	43	68	2	3
Technical check recommended	no	yes	43	68	3	4
Technical check recommended	no	yes	43	68	4	5
Technical check recommended	no	yes	43	68	5	6
Technical check recommended	no	yes	43	68	6	7

Measurements Table for UPSB125 and UPSB130

Show/hide table

Table 5
Description of the physical quantity	Word JBus (HEX)	Word MODBUS (decimal)	Unit
I1 (current phase 1) mains 1	100	257	A
I2 (I phase 2) mains 1	101	258	A
I3 (current phase 3) mains 1	102	259	A
I1 (current phase 1) mains 2	106	263	A
I2 (current phase 2) mains 2	107	264	A
I3 (current phase 3) mains 2	108	265	A
I1 (current phase 1) output	109	266	A
I2 (current phase 2) output	10A	267	A
I3 (current phase 3) output	10B	268	A
Battery current	10E	271	A
Device nominal active power	111	274	kW
U12 mains 1	115	278	V
U23 mains 1	116	279	V
U31 mains 1	117	280	V
U1N inverter	118	281	V
U2N inverter	119	282	V
U3N inverter	11A	283	V
U12 mains 2	121	290	V
U23 mains 2	122	291	V
U31 mains 2	123	292	V
U1N output	124	293	V
U2N output	125	294	V
U3N output	126	295	V
U12 output	127	296	V
U23 output	128	297	V
U31 output	129	298	V
U battery	12D	302	V
Output active power (phase 1)	130	305	kW
Output active power (phase 2)	131	306	kW
Output active power (phase 3)	132	307	kW
Output apparent power (phase 1)	133	308	kVA
Output apparent power (phase 2)	134	309	kVA
Output apparent power (phase 3)	135	310	kVA
Output total active power	136	311	kW
Output total apparent power	137	312	kVA
% output load level	139	314	(0-100)
Peak factor phase 1 x 100	13A	315	(0-400)
Peak factor phase 2 x 100	13B	316	(0-400)
Peak factor phase 3 x 100	13C	317	(0-400)
Power factor x 100	13D	318	(0-100)
Mains 1 frequency	13E	319	Hz
Inverter frequency	13F	320	Hz
Mains 2 frequency	140	321	Hz
Output frequency	141	141	Hz
Battery backup time	149	330	mn
Battery room temperature	14A	331	°C
Battery charging level	14B	332	%
Battery recharge duration	14F	336	mn
UPS rated power	209	522	kVA

Status Table for UPSB220

Show/hide table

Table 6
Status Description	Status to 0	Status to 1	Word JBus (Hex)	Word MODBUS (decimal)	JBus Bit	MODBUS Bit
Load Protected	no	yes	40	65	0	1
UPS coupled	no	yes	40	65	1	2
Unit general alarm	no	yes	40	65	2	3
System downgraded operation	no	yes	40	65	3	4
UPS in backup	no	yes	40	65	4	5
Battery low warning	no	yes	40	65	5	6
End of backup time (voltage or time)	no	yes	40	65	6	7
Operation on static switch	no	yes	40	65	7	8
Emergency stop	no	yes	40	65	B	12
Device ventilation fault	no	yes	40	65	E	15
Protected shut down for external contact	no	yes	40	65	F	16
UPS in online mode	no	yes	41	66	1	2
UPS in "eco" mode	no	yes	41	66	2	3
Unitary/parallel-connected UPS	no	yes	41	66	3	4
Status UPS ready for coupling	no	yes	41	66	4	5
Manual bypass switch (Q3BP)	open	closed	41	66	6	7
Battery end of life	no	yes	42	67	1	2
Battery test result	battery test OK	battery test error	42	67	2	3
Battery manual test in progress	no test in progress	test sequence activated	42	67	4	5
Battery compensation in progress	at rest	activated	42	67	5	6
Battery automatic test in progress	no test in progress	test sequence activated	42	67	8	9
Battery temperature out of tolerance	no	yes	42	67	A	11
Battery ventilation fault	no	yes	42	67	D	14
Battery circuit-breaker (QF1)	open	closed	42	67	F	16
Rectifier normal on/off	rectifier off	rectifier on	44	69	2	3
Mains 1 input switch (Q1)	closed	open	44	69	3	4
Mains 1 voltage ou of tolerance	no	yes	44	69	8	9
Mains 1 frequency out of tolerance	no	yes	44	69	B	12
Major coupling fault	no	yes	46	71	0	1
Maintenance position	no	yes	46	71	1	2
Mains 2 overload	no	yes	46	71	5	6
Mains 2 thermal overload	no	yes	46	71	6	7
Mains 2 frequency out of tolerance	no	yes	46	71	9	10
Mains 2 voltage out of tolerance	no	yes	46	71	A	11
Mains 2 phase out of tolerance	no	yes	46	71	B	12
Mains 2 input switch (Q4S)	closed	open	46	71	E	15
Bypass in free frequency	no	yes	47	72	8	9
Output switch (Q5N)	closed	open	47	72	B	12
Forced shut down for external contact	no	yes	47	72	C	13
Number of UPS ready sufficient for coupling	no	yes	47	72	F	16
Charger general fault	no	yes	49	74	0	1
Battery charged state	not in charge	in charge	49	74	3	4
Major inverter fault	no	yes	4C		1	2
Inverter overload	no	yes	4C	77	2	3
Inverter thermal overload	no	yes	4C	77	3	4
Inverter limitation	no	yes	4C	77	4	5
Inverter fuse fault	no	yes	4C	77	5	6
Output thermal overload	no	yes	4D	78	F	16
Output overload	no	yes	4F	80	0	1

Measurements Table for UPSB220

Show/hide table

Table 7
Description of the physical quantity	Word JBus (Hex)	Word MODBUS (decimal)	Unit
I1 (current phase 1) mains 1	100	257	A
I2 (current phase 2) mains 1	101	258	A
I3 (current phase 3) mains 1	102	259	A
I1 (current phase 1) inverter	103	260	A
I2 (current phase 2) inverter	104	261	A
I3 (current phase 3) inverter	105	262	A
I1 (current phase 1) mains 2	106	263	A
I2 (current phase 2) mains 2	107	264	A
I3 (current phase 3) mains 2	108	265	A
I1 (current phase 1) output	109	266	A
I2 (current phase 2) output	10A	267	A
I3 (current phase 3) output	10B	268	A
Battery current	10E	271	A
Device nominal active power	111	274	kW
U12 mains 1	115	278	V
U23 mains 1	116	279	V
U31 mains1	117	280	V
U1N inverter	118	281	V
U2N inverter	119	282	V
U3N inverter	11A	283	V
U12 inverter	11B	284	V
U23 inverter	11C	285	V
U31 inverter	11D	286	V
U1N mains 2	11E	287	V
U2N mains 2	11F	288	V
U3N mains 2	120	289	V
U12 mains 2	121	290	V
U23 mains 2	122	291	V
U31 mains 2	123	292	V
U1N output	124	293	V
U2N output	125	294	V
U3N output	126	295	V
U12 output	127	296	V
U23 output	128	297	V
U31 output	129	298	V
U battery	12D	302	V
Battery voltage end of backup threshold	12E	303	V
Output active power (phase 1)	130	305	kW
Output active power (phase 2)	131	306	kW
Output active power (phase 3)	132	307	kW
Output apparent power (phase 1)	133	308	kVA
Output apparent power (phase 2)	134	309	kVA
Output apparent power (phase 3)	135	310	kVA
Output total active power	136	311	kW
Output total apparent power	137	312	kVA
% output load level	139	314	(0-100)
Peak factor phase 1 x 100	13A	315	(0-400)
Peak factor phase 2 x 100	13B	316	(0-400)
Peak factor phase 3 x 100	13C	317	(0-400)
Power factor x 100	13D	318	(0-100)
Mains 1 frequency	13E	319	Hz
Inverter frequency	13F	320	Hz
Mains 2 frequency	140	321	Hz
Output frequency	141	322	Hz
Nominal backup time	148	329	mn
Battery backup time	149	330	mn
Battery room temperature	14A	331	°C
Battery charging level	14B	332	%
Battery recharge duration	14F	336	mn

Troubleshooting

Show/hide table




Illustration 19	g01995234
(1) Switches fro RS485 settings (SA2) (2) Switches for JBUS/MODBUS settings (SA1) (3) RS232 link configuration jumpers (4) RS485 communication port (5) RS232 communication port (6) Diagnostic LED (7) Card restart push button

Show/hide table

Table 8
Problem	Probable Cause	Remedy
The diagnostic LED (6) remains always OFF.	The card is not supplied with power.	Check that the card is correctly inserted and secured in the slot.
		Check that the system is energized.
		Remove the card and install the card again.

The diagnostic LED (6) remains always ON.	The card is blocked.	Check that the push button (7) is released (not pressed).
The diagnostic LED (6) remains always ON.	The card is blocked.	Remove the card and install the card again.

JBUS/RS232 communication is not operational.	Communication parameters are not correct.	Wait 2 minutes after the power is turned on or the card is restarted.
	The RS232 connection is faulty.	Check that the RS485 port (4) and the RS232 port (5) and not both connected.
		Check that the Rx/Tx jumper position (3) is in accordance with the serial cable that is used.
		Check that the communication parameters that are used by the JBUS master application are in accordance with the card parameters.
		Check the link with the default parameters.

JBUS/RS485 communication is not operational.	Communication parameters are not correct.	Wait 2 minutes after the power is turned on or the card is restarted.
	The RS485 connection is faulty.	Check that the RS485 port (4) and the RS232 port (5) and not both connected.
		Check that the communication parameters that are used by the JBUS master application are in accordance with the card parameters.
		Check that the link with the default parameters.
		Validate the communication parameters by checking the card in a point to point RS232 link.

The access of the configuration menu is impossible.	The maintenance mode is not activated.	Press the push button (7) for more than 3 seconds.
	The RS232 connection is faulty.	Check that the Rx/Tx jumper position (3) is in accordance with the serial cable that is being used.
		Check the terminal settings: 9600 bauds, even, seven data bits, one stop bit
		Check the position of the SA1 switches (2).