Monico CDL Operating instructions

Monico Gateway from Cummins®
Version 1.03
Installation and Operation Guide
Monico, Inc.
18530 Klein Church Road
Spring, TX 77379
281.350.8751
[e-mail]

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Table of Contents
1 Introduction....................................................................................................................................................4
2 Power Supply..................................................................................................................................................6
3 EMC Installation Guidelines ...........................................................................................................................8
4 Installation......................................................................................................................................................9
4.1 Connection and Engine Controller .......................................................................................................10
4.1.1Monico PCML Gateway to Modlon Gateway..................................................................................10
4.1.2Monico PCCx Gateway to PCC1.x/PCC2.x/PCC3.x Controller..........................................................11
4.2 Troubleshooting LEDs...........................................................................................................................12
STS –Status LED ......................................................................................................................................12
4.3 Host Connections .................................................................................................................................13
5 MONICOVIEW II™ PROGRAMMER ...............................................................................................................14
5.1 USB Driver Installation .........................................................................................................................14
5.1.1USB Driver Troubleshooting............................................................................................................15
5.2 Window Layout ....................................................................................................................................16
5.2.1The Navigation Pane .......................................................................................................................16
5.2.2The Resource Pane..........................................................................................................................16
5.2.3The Editing Pane..............................................................................................................................16
5.3 Obtaining/Updating the Gateway Configuration.................................................................................17
5.4 Setting the IP Address ..........................................................................................................................17
5.5 Enabling TCP/IP Download...................................................................................................................18
5.6 Securing the Configuration (Optional) .................................................................................................19
5.7 Adjusting Serial Port Settings ...............................................................................................................19
5.8 Enable/Disbale Devices ........................................................................................................................20
5.9 Viewing Live [Real Time] Data..............................................................................................................20

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6 Configuration and Setup Of The Gateway PLUS...........................................................................................22
6.1 The Web Server....................................................................................................................................22
6.1.1Web Server Properties ....................................................................................................................22
6.1.2Using the Security System...............................................................................................................23
6.1.3Using Services..................................................................................................................................25
6.1.4Using Electronic Mail.......................................................................................................................27
6.2 Accessing the Virtual HMI ....................................................................................................................32
7 APPENDIX A –Gateway Serial Ports.............................................................................................................34
8 Appendix B - SPECIFICATIONS ......................................................................................................................35

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1Introduction
This document covers the installation and setup of the Monico Gateway from Cummins®. The
Monico Gateway™KIT from Cummins®offers an easy to install, preconfigured protocol converter
specially designed for Cummins Power Generation applications. Each KIT comes complete with all
required accessories, instructions and user manual to perform and support most standard
installations encountered. Your Monico Gateway provides data conversation for generators with
PCC1.x, 2.x and 3.x as well PCC2100, PCC3200 and PCC3100 series controllers to three standard
preconfigured protocols: BACnet UDP, SNMP and Modbus TCP. All data is pre-scaled in standard
units with gains applied for effortless integration into your PLC, SCADA, BMS or PC system. In
addition to protocol conversion the Monico Gateway PLUS™provide a web server, security
manager, FTP access and synchronization, virtual HMI, data logging, SMTP / SMS alert notification
and custom logic capabilities.
When you are correctly connected you can view live data with the use of MonicoView II software
which is available at http://www.monicoinc.com. All data values are in pre-assigned registers to
minimize setup time. It is our intention to always provide a product that requires little or no setup
to function in a wide variety of applications. However, any of our programs are modifiable using
MonicoView II software. Be sure to check the website for the latest software revisions before
installation. The major features are listed below:
• Standard Version offers BACnet, SNMP, and Modbus TCP, over Ethernet. Serial interfaces on the
above mentioned protocols can be provided using an optional serial interface card
• User Interface via a USB connection that allows you to configure the ports and see exactly
which parameters are responding on your installation.
• I ntegral 24 VDC Power Supply
• Designed to be mounted on Din-Rails, so no adapters are needed
• Uses modular jacks for connections which minimizes wiring errors, especially when using our
optional factory cables
• Does not require complicated address offsets.
• Does not require complicated Enable/Disable Masks as all parameters are default enabled. If
necessary, the user can deactivate individual registers or ports via the User Interface, but due to
the drastic increase in speed it should not be necessary for monitoring purposes
• Allows for other host protocols such as BACnet and can push parameters directly to the end
PLC, SCADA, or BMS system. Special instructions for these versions are covered in the appendix
sections of this manual.
As always, you can count on Monico’s “No Questions Asked” support policy. We are committed to
timely support of every customer who contacts us for help regardless of where the gateway was
purchased. The only thing that matters to Monico is a successful installation.

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Gateway Connection Overview
Figure 1

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2Power Supply
All Monico Gateways™ require a regulated 24 VDC +/- 10% power source with 1000 ma power maximum.
Monico Gateway from Cummins® KITS come with a 110 VAC-24 VDC power supply. If 110 VAC is not
available, you must use a Class 2 or SELV rated 24 VDC power supply. It is recommended that you use
either an isolated DC-DC power supply, or properly grounded engine 24v batteries to power the
Gateway. When power is applied, the green STS light will function. If this light is blinking, then no setup
file is installed or it is currently loading a file. If this light is solid, then a setup file is resident and
operating.
Figure 2
CAUTION
Reversing wire polarity may cause damage to your Gateway. This damage is not covered by warranty. If
in doubt about which wire is which on your power supply, check with a meter.
When using an external power supply, it is very important that the power supply is mounted correctly if
the unit is to operate reliably. Please take care to observe the following points:
The power supply must be mounted close to the unit, with usually not more than 6 feet (1.8 m) of cable
between the supply and the Gateway. Ideally, the shortest length possible should be used. The wire used
to connect the Gateway’s power supply should be at least 22-gage wire. If a longer cable run is used, a

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heavier gage wire should be used. The routing of the cable should be kept away from large contactors,
inverters, and other devices which may generate significant electrical noise.
A power supply is provided with all Monico Gateway from Cummins® Kits and has a rating of Class 2 or
SELV. A Class 2 or SELV power supply provides isolation to accessible circuits from hazardous voltage levels
generated by a mains power supply due to single faults. SELV is an acronym for “safety extra-low voltage.”
Safety extra low voltage circuits shall exhibit voltages safe to touch both under normal operating
conditions and after a single fault, such as a breakdown of a layer of basic insulation or after the failure of a
single component has occurred.

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3EMC Installation Guidelines
Although all Monico Gateways™are designed with a high degree of immunity to Electromagnetic
Interference (EMI), proper installation and wiring methods must be followed to ensure compatibility in
each application. The type of electrical noise, source or coupling method into a unit may be different for
various installations. Cable length, routing, and shield termination are very important and can mean the
difference between a successful or troublesome installation. Listed are some EMI guidelines for a
successful installation in an industrial environment.
To reduce the chance of noise spikes entering the unit via the power lines, connections should be
made to a clean source. Connecting to circuits that also power loads such as contactors, relays, motors,
solenoids etc. should be avoided.
The unit should be mounted in a metal enclosure, which is properly connected to protective earth.
Use shielded (screened) cables for all Signal and Control inputs. The shield (screen) pigtail connection
should be made as short as possible. The connection point for the shield depends somewhat upon the
application.
Listed below are the recommended methods of connecting the shield, in order of their effectiveness.
oConnect the shield to earth ground (protective earth) at one end where the unit is mounted.
oConnect the shield to earth ground at both ends of the cable, usually when the noise source
frequency is over 1 MHz.
oConnect the shield to common of the Data Station and leave the other end of the shield
unconnected and insulated from earth ground.
Never run Signal or Control cables in the same conduit or raceway with AC power lines,
conductors feeding motors, solenoids, SCR controls, and heaters, etc. The cables should be
run through metal conduit that is properly grounded. This is especially useful in applications
where cable runs are long and portable two-way radios are used in close proximity or if the
installation is near a commercial radio transmitter. Also, Signal or Control cables within an
enclosure should be routed as far away as possible from contactors, control relays,
transformers, and other noisy components.
Long cable runs are more susceptible to EMI pickup than short cable runs. Therefore, keep
cable runs as short as possible.
In extremely high EMI environments, the use of external EMI suppression devices is effective.
The following EMI suppression devices (or equivalent) are recommended: Ferrite Suppression
Cores for signal and control cables:
oFair-Rite part number 0443167251 (RLC part number FCOR0000) TDK part number ZCAT3035-
1330A
oSteward part number 28B2029-0A0
oLine Filters for input power cables:
oSchaffner part number FN610-1/07 (RLC part number LFIL0000) Schaffner part number FN670-
1.8/07
oCorcom part number 1 VR3

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4Installation
The DIN rail should be mounted horizontally so that the unit’s ventilation holes are vertical in relation to
cabinet orientation. A minimum clearance of 1 inch (25.4 mm) should be maintained above and below all
units in order to ensure proper thermal regulation. Also ensure that enough cable clearance is allowed at
the front of the Gateway to allow cable connections to the Gateway’s interface ports.
Figure 3

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Connection and Engine Controller
4.1.1 Monico PCML Gateway to Modlon Gateway
This section covers the installation and connection of the Monico PCML LE or GT Gateway to
Cummins Controllers and Transfer Switch Gear which employ the Lonworks network. Connection
interface between the Monico Gateway and Lonworks network is made via the Cummins Modlon
Gateway. Each Modlon Gateway supports up to 5 Engines and 5 Transfer Switches and each
device must have a Lonworks Network card installed. Subsequently, the standard Monico PCML
Gateway configuration is setup to support up to 5 Engines and 5 Transfer Switches via a single
Cummins Modlon Gateway.
The CMS-MCGT-PCML-KIT and CMS-MCLE-PCML-KIT come with the following hardware. Please
locate and ensure that you have the following. Contact Monico or your local Cummins Dealer if
any of items are missing.
oQTY (1) Monico Gateway
oQTY (1) CBL-DB9MNMRJ12-1, 1’ RJ12 to DB9 serial cable
oQTY (1) PQS3.241, 110VAC to 24VDC, 1 Amp power Supply
Please review section 3, EMC Installation Guidelines before proceeding.
Locate and install the Monico Gateway and Power Supply to a DIN rail mount.
Ensure that the Cummins Modlon Gateway is mounted next to the Monico Gateway as shown in
Figure 4
Plug the RJ12 connection end of the serial cable into the Monico’s RS232 port and the DB9 end
into the top of the Modlon Gateway.
Connect 24vdc from the power supply to both the Monico Gateway and Cummins Modlon
Gateway.
By default, the Monico Gateway is set to communicate with the Cummins Modlon Gateway via
Modbus RTU on RTU#1 at communication parameters of 38400 baud, 8 data bits , no parity, 1
stop bit (38400,8,N,1). Ensure that the Modlon Gateway is configured appropriately and once it
has been commissioned, apply power to the system.
Note the LED activity on the RS232 port of the Monico Gateway. If it is communicating properly,
you should see both the red and green LEDs alternating at a fast rate. If they are not, see section
Modlon Gateway
DB9 Connector PCC Controller
[PCC2100 shown]
LonWorks Network
Monico Gateway
Monico CBL-DB9MNMRJ12-1
RJ12 to DB9 Cable
Power [min 22 gage]
Power
Supply
Figure 4

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4.1.2 Monico PCCx Gateway to PCC1.x/PCC2.x/PCC3.x Controller
This section covers the installation and connection of the Monico PCCx LE or GT Gateway to
Cummins PCC1.x/PCC2.x/PCC3.x Controllers.
The CMS-MCGT-PCCx.XL-KIT and CMS-MCLE-PCCx.XL-KIT come with the following hardware.
Please locate and ensure that you have the following. Contact Monico or your local Cummins
Dealer if any of items are missing.
oQTY (1) Monico Gateway
oQTY (1) CBL-485-1, 1’ RS485 serial cable with flying leads
oQTY (1) PQS3.241, 110VAC to 24VDC, 1 Amp power Supply
oQTY (1) BB485OPDRI, RS485 Isolated Repeater
Please review section 3, EMC Installation Guidelines before proceeding.
Locate and install the Monico Gateway, Power Supply, and Isolated Repeater to a DIN rail
mount.
Ensure the Isolated Repeater is mounted next to the Monico Gateway as shown in Figure 5
Plug the RJ45 connection end of the serial cable into the Monico’s RS485 port and the flying
lead ends, marked as RS485 TXB (+) and RS485 TXA (-), to the Isolated Repeater as shown in
figure 3.
Using Belden 984x or equivalent communication cabling, connect the Repeater to the
controller as shown in Figure 5 noting that the shield should ONLY be connected at the
controller end.
Set the dip switch settings on both the top and bottom ports of the Isolated Repeater as
shown in Figure 5. By default, the Monico Gateway is set to communicate with the Controller
via Modbus RTU on RTU#2 at communication parameters of 9600 baud, 8 data bits , no
parity, 1 stop bit (9600,8,N,1). If different communication parameters are desired, refer to the
Repeater documentation).
Connect 24vdc from the power supply to both the Monico Gateway and Isolated Repeater and
apply power to the system.
Note the LED activity on the RS232 port of the Monico Gateway. If it is communicating
properly, you should see both the red and green LEDs alternating at a fast rate. If they are not,
see section Error! Reference source not found. Error! Reference source not found..
Belden 984x
B(+)
TB15
[Shield] TB15-1
(+) TB15-3
(-) TB15-4
Monico Gateway
PCC 1.x/2.x/3.x Controller
C (-)
Monico CBL-485-1
RJ45 to Flying Lead
B (+)
C (-)
Recommended Dip Switch
Settings [9600,8,N,1]
Isloated
Repeater
Power [min 22 gage]
Power
Supply
Figure 5

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Troubleshooting LEDs
STS –Status LED
The green Status LED provides information regarding the state of the Gateway. This includes indication of
the various stages of the start-up routine (power-up), and any errors that may occur.
Startup Routine
3.2.2 –Serial Host Ports –TX/RX/LEDs
3.2.3 –TCP/IP Ethernet Port LEDs
These LED’s are the first step in troubleshooting communications issues. Please note the action of these
LED’s, IN DETAIL, when contacting the Monico for technical support.
LED
Indication
Rapidly Flashing
Gateway is currently loading program
Steady
Gateway is operating normally
LED
Indication
Green
Transmitting
Red
Receiving
LED
Indication
Yellow (Solid)
Link Established
Yellow (Flashing)
Network Activity
Green
10 BASE-T Communications
Amber
100 BASE-T Communications

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Host Connections
The Host device (PLC, HMI, Building Management System, etc.) is connected to the Monico Gateway
through the Ethernet Port (RJ-45 Jack-Shielded). By default the Monico Gateway supports Modbus TCP
Slave, BACnet UDPIP Slave, & SNMP over Ethernet. The Monico Gateway is fully capable of providing data
via hundreds of other protocols and/or serially as an option. The above mentioned protocols can be
established at either 10 BASE-T or 100 BASE-TX. The Gateway’s RJ45 jack is wired as a NIC (Network
Interface Card). For example, when wiring to a hub or switch use a straight-through cable, but when
connecting to another NIC use a crossover cable. Default IP Address is 192.168.1.10
As stated, the default Monico Gateway protocols include Modbus Slave, BACTnet UDPIP Slave, and SNMP
over Ethernet. The data maps for each configuration can be downloaded from
http://www.monicoinc.com/support .

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5MONICOVIEW II™ PROGRAMMER
The MonicoView II™ Programmer is a critical part of the product. This free software is used to develop
programs or modify files supplied from the factory to meet your needs. Please check on our website for
the latest version at www.monicoinc.com/support. MonicoView II™ is used to adjust port settings for each
available port, to disable unused ports to maximize performance, to delete unused or unavailable
parameters from polling blocks, and to view live data for all data blocks. MonicoView II™ can also be used
to modify any section of the unit programming. However, make sure to select <LINK><EXTRACT> from the
menu to save a copy of the original .mv2 program before making changes. If you click on <UPDATE>
before OPENING a valid file or <EXTRACT>, it will result in a blank file being downloaded to the Gateway
which will render it ineffective. If this should occur, contact Monico and we can send a copy of the file
supplied with the Gateway. Please make note the Version Number on the label on the right side of the
Gateway, so we can identify the appropriate file. Whenever upgrading MonicoView II™ Programmers
versions, us the REPAIR option. The connection is established through a standard USB printer cable that
has a rectangular connector on one end and a square connector with two rounded edges on the other.
Make sure to select <LINK><OPTIONS> from the menu and set the connection to USB.
USB Driver Installation
Each time you connect to a new Gateway unit, you should see the Windows “Found New Hardware”
screen and the required drivers should automatically be installed.Should you be prompted to go to
Windows Update to find a driver, select “No, not at this time” and click “Next”. This will bring up the screen
shown in Figure 6 and the “Install Automatically” should be selected by default.
Figure 6
Click “Next” to continue and you see the screen below stating that the driver you are installing has not
been tested by Microsoft. Select “Continue Anyway”.

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Figure 7
Click “Finish” when this screen is done. There is another driver that will need to be loaded, but it will not be
found until you download the program to the Gateway. Note that after the initial installation or update of
the Gateway program, Microsoft will find new hardware again and you will go through the same process
again, but instead of calling it “G3 Loader”, it will be called “G3 HMI”.
5.1.1 USB Driver Troubleshooting
In some cases, connecting a computer to AC can cause electrical grounding issues and will be evident due
to intermittent errors during USB communication. More than likely, this is due to the fact that the
computer’s ground is not referenced to the same ground as the Gateway. To resolve this, simply unplug
your computer from the AC power source during programming and update operations.
Depending on the administrative rights of your computer, the USB driver may not install correctly the first
time the driver is installed. This will be evident if a USB connection cannot be made to the Gateway. The
following steps should be followed to correct this problem.
Ensure that the MonicoView II connection link is set to USB via <Link><Options> from the menu.
Ensure that the G3HMI USB driver has installed correctly in Device Manager.
Go into Device Manager via System in the control panel or right-click on My Computer and select
<Properties><Device Manager>.
Look for a device with a Yellow Triangle next to it. It may be under “Other Devices” or “Unknown
Devices”.

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Figure 8
Right-Click on the driver and select Properties from the drop down menu
From the Driver tab select Update Driver and browse to and select one of the following folders:
oWindows 32 - “C:\Program Files\Monico\MonicoView II\Device”
oWindows 64 - “C:\Program Files (x86)\Monico\MonicoView II \Device”
Note: Do not select any sub-folders under the Device folder. Select <OK> and allow the driver to install.
Contact Monico Tech Support should this not resolve the problem.
Window Layout
To run MonicoView II, select the MonicoView II icon in the Monico section of your Start Menu. After a
couple of seconds, MonicoView II will appear. The main MonicoView II window is comprised of three
different panes as shown in Figure 9 below…
5.2.1 The Navigation Pane
The left-hand portion of the window is called the Navigation Pane. It is used to move between different
categories of items within a MonicoView II configuration file. Each category is represented by a bar at the
base of the pane, and clicking on that bar will navigate to that section. The top section of the Navigation
Pane shows the available items in the current category, and provides a toolbar to allow those items to be
manipulated.
5.2.2 The Resource Pane
The right-hand portion of the window is called the Resource Pane. It is used to access various items that
are of use when editing the current category. Just like the Navigation Pane, it contains a number of
categories which can be accessed via the category bars.
5.2.3 The Editing Pane
The central portion of the window is used to edit the currently selected item. Depending on the selection,
it may contain a number of tabs, each showing a given set of the properties for that item, or it may contain
an editor specific to the item that you are working on.

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Figure 9
Obtaining/Updating the Gateway Configuration
Before editing or making any changes to the Gateway, you must obtain the current configuration which
resides in the Gateway. To do this:
Connect the computer to the Gateway via the USB cable and make sure that the Gateway is
powered.
Ensure that “USB” type connection is selected from the <Link><Options> menu and then select OK.
From the menu, select <Link><Extract> to download the configuration from the Gateway to the
computer and then save the configuration locally to your computer.
From this point, the configuration will reside locally on your computer and any changes made will need to
be downloaded to the Gateway before taking effect. To upload changes, simply select <Link><Update>
from the menu.
Setting the IP Address
By default, the IP parameters of the Gateway are set to the following:
oIP Address: 192.168.1.10
oNetwork Mask: 255.255.255.0
oGateway: 0.0.0.0
You can easily change these to whatever you wish by performing the following steps.
Make sure you have “Extracted” the configuration from Gateway and then highlight the “Network”
interface in the Navigation Pane
Change the IP Parameters by selecting the “Ethernet 1” tab in the center Settings Pane and
entering the required parameters in the Port Settings area as shown in Figure 10.
Upload the changes to the Gateway by selecting <Link><Update> from the menu.
Test your connection by performing a “ping” over the network.

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Figure 10
Enabling TCP/IP Download
Any function accomplished through the USB port can ALSO be performed over Ethernet however; you must
ensure that a Compact Flash is installed whenever Firmware Updates are performed. A Firmware Update
occurs whenever the unit is updated with a newer version of MonicoView II software than what it was
originally programmed with. Keep in mind that you must first use the USB connection to set the Gateway
to the required IP parameters as described in section 5.4, Setting the IP Address. You must also ensure
that Remote Update is enabled and that the Port number is set to 789 as shown in Figure 11.Once the
above mentioned has been performed over USB, you may perform database updates and port setting
changes remotely over a LAN by setting your connection type to “TCP/IP” from <Link><Options>.
Figure 11

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Securing the Configuration (Optional)
The Monico Gateway gives a user the option to lock-down the configuration securing it from unauthorized
extraction. The <Link><Support Upload> command can be used to instruct the Gateway as to whether or
not it should include the information necessary to support database uploads when sending a database to a
target device. This setting is stored in the database, and can thus be configured on a per-file basis.
Supporting upload will slow the download process somewhat and may fail with extremely large databases
containing many embedded images, but it will ensure that, should you lose your database file, you will be
able to extract an editable image from the device. Note that by default, Support Upload is enabled on all
Monico configurations however, if you choose to have Support Upload disabled and lose your database file;
you will not be able to reconstruct your file without starting from scratch. It is therefore IMPERATIVE that a
Master Copy be properly maintained when Support Upload is disabled.
Adjusting Serial Port Settings
By default, the Monico Gateway has three serial ports including two RS-232 ports and an RS-485 port.
Monico View II can be used to configure and/or adjust the communication settings for any of the serial
ports. For example, Figure 12 shows the default Modbus RTU Master Communication settings when
interfacing to a Modlon Gateway as 38400, 8, N, 1. If instead you wished to change the baud rate to 9600,
you would simply highlight the Modlon device and change its baud rate to 9600 and then upload the
changes to the Gateway. Note that additional serial ports can be provided as an option on custom
applications.
Figure 12

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Enable/Disbale Devices
By default, the Monico Gateway comes pre-configured with all pertinent serial ports active and all Ethernet
interfaces enabled. Each interface has at least one “device” specified under its heading. The Ethernet
interface supports up to 4 devices (protocols) specified and active at any given time whereas serial ports
can only have 1. To keep processing overhead to a minimum, it is recommended that all unneeded devices
be disabled. This can be accomplished by simply highlighting the device and selecting “No” under Enable
Device in the “Device Settings” area of the Editing (center) pane. Note that when the device is disabled, a
red X will appear over the device as shown in Figure 13.
Figure 13
Viewing Live [Real Time] Data
MonicoView II supports “Live Data” viewing within a “Watch Window”that allows you to see the actual data
acquired by the Monico Gateway in real time. This is a great trouble-shooting aid in determining what values
are being acquired by the Gateway. Note that you must first be connected to the Gateway via USB or
Ethernet in order to utilize this function. You can view entire blocks of data by right-clicking on the desired
block from the Communications tab and selecting “Watch Block”. A Watch Block dialogue box will appear
as shown in Figure 14. Once open, click the “View Online” button to acquire the data within the block in