Proconx GCP-MG User manual

GCP-MG
GCP Modbus
gateway
Usermanual
Edition 1.2
UMGCPMG-2201

GCP-MG
GCP Modbus gateway: Usermanual
Copyright © proconX Pty Ltd. All rights reserved.
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express written consent from the copyright holders.
proconX is a trademark of proconX Pty Ltd. Modbus is a registered trademark of Schneider Automation Inc. All other product and brand
names mentioned in this document may be trademarks or registered trademarks of their respective owners.
Disclaimer
proconX Pty Ltd makes no warranty for the use of its products, other than those expressly contained in the Company’s standard warranty
which is detailed in the Terms and Conditions located on the Company’s Website. The Company assumes no responsibility for any errors
which may appear in this document, reserves the right to change devices or specifications detailed herein at any time without notice,
and does not make any commitment to update the information contained herein. No licenses to patents or other intellectual property
of proconX are granted by the Company in connection with the sale of proconX products, expressly or by implication. proconX products
are not authorized for use as critical components in life support devices or systems.
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Your feedback and comments are always welcome. It helps improving this product.
Contact
For further information about the GCP-MG product please visit https://www.proconx.com/gcpmg

UMGCPMG-2201 iii
Contents
Important user information ......................................................................................... v
Safety Precautions ................................................................................................ v
Document conventions ........................................................................................ vi
1 Introduction ............................................................................................................. 1
Features ................................................................................................................ 2
Quick start checklist ............................................................................................. 3
2 Description ............................................................................................................... 5
LED indicators ...................................................................................................... 5
Principles of operation ......................................................................................... 6
3 Installation ................................................................................................................ 9
Regulatory notes .................................................................................................. 9
Unpacking, handling and storage ........................................................................ 9
Before connecting anything ................................................................................. 9
DIN rail mounting and removal ......................................................................... 10
Mounting rules .................................................................................................. 10
Powering the GCP-MG ....................................................................................... 11
Wiring the CAN interface ................................................................................... 11
Wiring the RS-485 Modbus interface ................................................................. 12
Wiring the RS-232 Modbus interface ................................................................. 13
Connecting Ethernet .......................................................................................... 14
Connecting to the diagnostic port ..................................................................... 15
4 Ethernet & IP configuration ................................................................................... 17
IP setup using a web browser and a cross-over network cable .......................... 17
IP setup using a terminal program like HyperTerminal ....................................... 18
Temporarily changing the IP settings on your PC ............................................... 19
5 Web browser based management ......................................................................... 21
Connecting to the GCP-MG ............................................................................... 21
Monitoring and diagnostic ................................................................................ 22
Device status .............................................................................................. 22
Modbus connection status ......................................................................... 23
CAN communication status ........................................................................ 24
Finding the firmware version and serial number ........................................ 26
Configuring and commissioning ........................................................................ 26
Configuring Ethernet and IP ....................................................................... 27
Configuring GCP-30 and LS 4 Modbus access ............................................ 28
Configuring serial line Modbus .................................................................. 29
Remote restarting the device ..................................................................... 30
6 Modbus data reference .......................................................................................... 33
GCP-30 MUX data table 3:0001 ........................................................................ 34
Allocation with options SB03 and SC06 ..................................................... 37
GCP-30 floating point table 3:1001 ................................................................... 37
GCP-30 remote control data table 4:0001 ......................................................... 39
LS 4 MUX data table 3:0001 ............................................................................. 39
LS 4 floating point data table 3:1001 ............................................................... 41
LS 4 remote control data table 4:0001 .............................................................. 42
7 Decommissioning ................................................................................................... 43
Disconnecting ..................................................................................................... 43
Disposal .............................................................................................................. 43

iv UMGCPMG-2201
A Specifications ......................................................................................................... 45
Dimensions ......................................................................................................... 47
References .................................................................................................................. 49
Glossary ..................................................................................................................... 51
Index .......................................................................................................................... 53
Figures
2.1 Location of connectors .......................................................................................... 5
2.2 Gateway operation ................................................................................................ 7
3.1 CAN bus topology ............................................................................................... 12
5.1 Device management and configuration via the web browser .............................. 21
5.2 Overview page .................................................................................................... 22
5.3 Modbus status page ........................................................................................... 23
5.4 CAN communication status page ........................................................................ 25
5.5 About page ......................................................................................................... 26
5.6 Ethernet and IP settings page ............................................................................. 27
5.7 IP settings changed confirmation ........................................................................ 27
5.8 GCP-30 settings page .......................................................................................... 28
5.9 Modbus settings page ......................................................................................... 29
5.10 Restart device page ........................................................................................... 30
5.11 Restart confirmation page ................................................................................. 30
A.1 Enclosure dimensions .......................................................................................... 47
Tables
2.1 LED diagnostic codes ............................................................................................ 6
3.1 Power supply connector pinout .......................................................................... 11
3.2 CAN connector pinout ........................................................................................ 11
3.3 RS-485 connector pinout .................................................................................... 13
3.4 RS-232 Modbus connector pinout ...................................................................... 14
3.5 Ethernet connector pinout .................................................................................. 14
3.6 Diagnostic port connector pinout ....................................................................... 15
6.1 Supported Modbus function codes ..................................................................... 33
6.2 Modbus slave ID relationship .............................................................................. 33
6.3 Modbus exception codes .................................................................................... 34
6.4 Modbus addresses for GCP-30 MUX values ......................................................... 35
6.5 Modbus addresses for SB03 Cat CCM and SC06 MTU MDEC options .................. 37
6.6 Modbus addresses for GCP-30 floating point data table ..................................... 38
6.7 Modbus addresses for GCP-30 remote control .................................................... 39
6.8 Modbus addresses for LS 4 MUX values ............................................................. 40
6.9 Modbus addresses for LS 4 floating point data table .......................................... 41
6.10 Modbus addresses for LS 4 remote control ....................................................... 42

Important user information
UMGCPMG-2201 v
Important user information
This manual explains how to install, operate and configure a GCP-MG. This device may
only be used for the applications described in this document.
These instructions are intended for use by trained specialists in electrical installation
and control and automation engineering, who are familiar with the applicable national
standards and safety procedures.
Safety Precautions
ELECTRICAL HAZARD
• This equipment must be installed and serviced only by qualified personnel. Such
work should be performed only after reading this entire set of instructions.
• Before performing visual inspections, tests, or maintenance on this equipment,
disconnect all sources of electric power. Assume that all circuits are live until they
have been completely de-energized, tested, and tagged. Pay particular attention
to the design of the power system. Consider all sources of power, including the
possibility of backfeeding.
• Apply appropriate personal protective equipment and follow safe electrical
practices.
• Turn off all power supplying the equipment in which the GCP-MG is to be installed
before installing, wiring or removing the GCP-MG.
• Always use a properly rated voltage sensing device to confirm that power is off.
• The successful operation of this equipment depends upon proper handling,
installation, and operation. Neglecting fundamental installation requirements
may lead to personal injury as well as damage to electrical equipment or other
property.
Failure to follow these instructions could result in death or serious injury!

vi UMGCPMG-2201
Document conventions
Throughout this manual we use the following symbols and typefaces to make you aware
of safety or other important considerations:
Indicates a potentially hazardous situation that, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation that, if not
avoided, could result in damage to equipment.
Indicates information that is critical for successful applica-
tion and understanding of the product.
Provides other helpful user information that does not fall in
above categories.
Provides supplemental user information.
Acronym This typeface is used to introduce acronyms or product
names.
Command This typeface is used to represent commands, prompts, in-
put fields and filenames. In the context of programming
it is used for functions, variable names, constants or class
names.
Placeholder This typeface is used to represent replacable text. Replace-
able text is a placeholder for data you have to provide, like
filenames or command line arguments.
User input This typeface is used to represent data entered by the user
or buttons.
Screen output
Screen output or program listing

Introduction
UMGCPMG-2201 1
Chapter 1.Introduction
The GCP-MG is a next-generation Modbus/CAN gateway specifically designed to interface
Woodward’s GCP-30 Series Genset Controls and LS 4 Circuit Breaker Controls with
Modbus networks.
The GCP-MG gateway has been developed in cooperation with Woodward to ensure the
highest possible degree of interoperability with Woodward equipment.
The gateway features CAN, serial RS-232 and RS-485 ports as well as an Ethernet port and
can be mounted on a DIN rail. On the CAN side it implements the Woodward CAL protocol
to connect to the GCP controls. On the serial ports and on Ethernet it implements a
Modbus server (Modbus RTU and Modbus/TCP) and accepts connections from Modbus
master devices like PLCs and SCADA systems.
Usage and configuration of the gateway is simple and conveniently performed using a
web browser which connects to the embedded web server.
Possible areas of application are:
• PLC connection
• Operator panel interfacing
• HMIs
• SCADA integration
• Power station automation

2UMGCPMG-2201
• Gen set control
• Remote control & monitoring
• Data logging
Features
The GCP-MG gateway provides the following key features:
• Modbus/TCP protocol (Ethernet)
• Modbus RTU protocol (either RS-232 or RS-485, software configurable)
• Interfaces with up to 16 GCP-30 controls and up to 8 LS 4 controls
• Full support of Option SB03 (Cat CCM) and Option SC06 (MTU MDEC)
• Modbus register layout compatible with GW 4
• Dedicated Modbus slave ID for each GCP-30 and LS 4 control
• Large internal buffer for data
• Complete data set of one GCP-30 unit can be read with a single Modbus transaction
• Integer/Exponent value pairs for voltages, power and currents are additionally
represented as 32-bit floating point registers
• Transparent handling of data guarantees compatibility with future Woodward
firmware updates
• Serial baud rate up to 115200 bps
• Support of Modbus function codes 03, 04, 06 and 16
• Concurrently one Modbus serial line and up to two Modbus/TCP connections
• Low configuration overhead, just an IP address
• Embedded web server for easy configuration and commissioning using a web browser
• Firmware upgradeable via Ethernet
• Status LEDs for power, Ethernet link, device status and communication status
• 24 V DC (10-30 V) power supply
• DIN rail mountable

Introduction
UMGCPMG-2201 3
Quick start checklist
• Read this set of instructions properly and in its entirety.
• Mount the unit.
• Connect the power. Do not connect yet CAN bus or serial ports.
• Configure the Ethernet communications settings with a web browser (using an
Ethernet crossover cable) or with a terminal program like HyperTerminal (using a null
modem cable)
• Configure the CAN bus settings.
• Configure the serial line communication settings.
• Configure the operational aspects of the device.
• Wire CAN bus.
• Wire serial line interfaces.

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4UMGCPMG-2201

Description
UMGCPMG-2201 5
Chapter 2.Description
The power, CAN and RS-485 terminals are placed on the top side of the unit. The RS-232
and Ethernet connectors are placed on the bottom side of the unit as shown in the
following illustration:
TOP VIEW
BOTTOM VIEW
FRONT VIEW
Figure2.1:Location of connectors
 Clear front cover
 RS-232 Modbus connector
 Diagnostic port connector
 Ethernet connector
 DIN rail clip
 Power LED
 Ethernet link LED
 Device status LED
 Modbus/CAN status LED
 Power terminals
 RS-485 Modbus terminals
 CAN connector
LED indicators
Four LEDs located at the front panel indicate the status of the GCP-MG. The LEDs assist
maintenance personnel in quickly identifying wiring or communication errors.

6UMGCPMG-2201
A LED test is exercised at power-up, cycling each LED off, green and then red for
approximately 0.25 seconds. At the same time the power-on self test of the device is
performed.
The following table outlines the indicator condition and the corresponding status after
the power-on self-test has been completed:
LED Function Condition Indication
Off No power applied to the device.
Power Power Green Power supply OK
Off No Ethernet link
Link Ethernet link Green Ethernet link OK
Off The device has an unrecoverable fault; may need replacing.
Flashing green
1 s rate
Device operational but needs commissioning due to configuration
missing, incomplete or incorrect.
Green The device is operating in normal condition.
Flashing red
1 s rate
Device operational but has a fault listed which requires acknowledg-
ment.
Status1 Device status
Red The device has an unrecoverable fault; may need replacing. Flashing
sequence and rate of Status2 LED indicates fault class.
Off CAN connection OK, Connection time-out on Modbus
Green Both Modbus and CAN connection OK
Flashing red-green
1 s rate
Modbus connection OK, Connection time-out on CAN
Flashing red
1 s rate
Connection time-out on both CAN and Modbus
Status2 Communica-
tion status
Red The device has detected an error that has rendered it incapable of
communicating on CAN.
Table 2.1: LED diagnostic codes
Principles of operation
The GCP-MG establishes a communication channel to each GCP-30 and LS 4 unit
connected to the CAN bus. All GCP-30 and LS 4 units transmit multiplexed data values
which the GCP-MG stores in its internal data tables. A GCP-30 for example sends a new
value every 100 ms, a LS 4 every 200 ms.
The GCP-MG acts as a Modbus server on Ethernet and the serial interface. It accepts
connections and Modbus queries from Modbus master devices. The Modbus registers are
then served from the GCP-MG's internal data tables. Because of the data table buffering,
the Modbus can be polled significantly faster than the update rate on the CAN bus.
However faster poll rates would not offer higher update cycles of the data values. The
GCP-MG allows a maximum of 2 connections via Modbus/TCP and in addition one serial
connection via either RS-485 or RS-232.

Description
UMGCPMG-2201 7
Figure2.2:Gateway operation
For remote control, a Modbus master writes control words to a dedicated internal data
table which is then cyclically sent to the corresponding GCP-30 or LS 4 unit. One remote
control data table is processed every 100 ms. This makes the remote control update cycles
depend on the number of units enabled for remote control. For example if 3 GCP-30s
are enabled for remote control, it takes 300 ms to send all control words to all GCP-30s,
if all 16 GCP-30 and all 8 LS 4 units are enabled for remote control it takes 2.4 seconds
((16 + 8) x 0.1 s) to transmit all control words to the connected units.

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8UMGCPMG-2201

Installation
UMGCPMG-2201 9
Chapter 3.Installation
Regulatory notes
1. The GCP-MG is suitable for use in non-hazardous locations only.
2. The GCP-MG is not authorized for use in life support devices or systems.
3. Wiring and installation must be in accordance with applicable electrical codes in
accordance with the authority having jurisdiction.
4. This is a Class A device and intended for commercial or industrial use. This
equipment may cause radio interference if used in a residential area; in this case it
is the operator’s responsibility to take appropriate measures.
5. The precondition for compliance with EMC limit values is strict adherence to the
guidelines specified in this set of instructions. This applies in particular to the area
of grounding and shielding of cables.
FCC Notice (USA only)
This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated
in a commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction
manual, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the
user will be required to correct the interference at his own expense.
Industry Canada Notice (Canada only)
This Class A digital apparatus complies with Canadian ICES-003.
Unpacking, handling and storage
1. Please read this set of instructions. carefully before fitting it into your system.
2. Keep all original packaging material for future storage or warranty shipments of
the unit.
3. Do not exceed the specified temperatures.
Before connecting anything
1. Before installing or removing the unit or any connector, ensure that the system
power and external supplies have been turned off.
2. Check the system supply voltage with a multimeter for correct voltage range and
polarity.

10 UMGCPMG-2201
3. Connect the power supply cable and switch on the system power. Check if the
Power LED is lit.
4. Turn off system power.
5. Connect all I/O cables.
6. Once you are certain that all connections have been made properly, restore the
power.
DIN rail mounting and removal
The GCP-MG gateway is designed to be mounted on a 35 mm DIN rail according to DIN/
EN 50022. The enclosure features a 35 mm profile at the back which snaps into the DIN
rail. No tools are required for mounting. Please observe the rules outlined in the section
called “Mounting rules”.
2
1
Click
To mount the unit on a DIN rail, slot the top part of the
GCP-MG into the upper guide of the rail and lower the
enclosure until the bottom of the red hook clicks into
place.
2
1
To remove the GCP-MG from the DIN rail, use a screw
driver as a lever by inserting it in the small slot of the red
hook and push the red hook downwards. Then remove
the unit from the rail by raising the bottom front edge of
the enclosure.
Mounting rules
The enclosure provides protection against solid objects according to IP20 / NEMAType1
protection rating. When mounting the unit observe the following rules:
• No water splash and water drops
• No aggressive gas, steam or liquids
• Avoid dusty environments.
• Avoid shock or vibration

Installation
UMGCPMG-2201 11
• Do not exceed the specified operational temperatures and humidity range.
• Mount inside an electrical switchboard or control cabinet.
• Make sure there is sufficient air ventilation and clearance to other devices mounted
next to the unit.
• Observe applicable local regulations like EN60204 / VDE0113.
Powering the GCP-MG
Before connecting power please follow the rules in the section called “Safety Precau-
tions” and the section called “Before connecting anything”.
Power is supplied via a 3.81 mm 2-pin pluggable terminal block located at the top side
of the mounted unit (refer to Figure2.1, “Location of connectors”). The following table
and picture shows the power terminal socket pinout:
V+
V-
Pin Signal Function
1 V+ Positive voltage supply (10 - 30 V DC)
2 V- Negative voltage supply, DC power return
Table 3.1: Power supply connector pinout
Make sure that the polarity of the supply voltage is correct before connecting any
device to the serial and CAN ports! A wrong polarity can cause high currents on the
ground plane between the V- power supply pin and the CAN port and serial port
ground pins, which can cause damage to the device.
Wiring the CAN interface
The CAN interface connects to the GCP-30 and LS 4 devices.
The CAN connector is a male 9-pin D-sub type located at the top side of the mounted
unit (refer to Figure2.1, “Location of connectors”). It has industry standard CiA DS-102
pinout as shown in the following table and picture:
CAN_L
GND
CAN_H
GND
1
6
Pin Signal Function
1 NC
2 CAN_L CAN_L bus line
3 CAN_GND CAN ground
4 NC
5 NC
6 CAN_GND CAN ground
7 CAN_H CAN_H bus line
8 NC
9 NC
Table 3.2: CAN connector pinout

12 UMGCPMG-2201
• The network must be terminated at both ends with its characteristic impedance,
typically a 120 Ohm 1/4 W resistor.
• Maximum number of electrically connected CAN nodes is 64 1.
• Maximum CAN cable length is 250 m (820 ft) and is derated depending on bit rates
and cable type.
• Stub connections off the main line should be avoided if possible or at least be kept as
short as possible. Stub connections must not have terminating resistors.
• To ensure a high degree of electromagnetic compatibility and surge protection the
cable should be twisted pairs and shielded. An additional cable conductor or pair may
be used for the CAN_GND reference.
Do not connect the cable shield to the CAN_GND pins or the connector shell! Use
an external chassis ground connection to terminate the shield.
The following diagram illustrates a typical interconnection between GCP-30 units and
the GCP-MG:
GND
CAN-L
CAN-H
GND
GND
CAN-L
CAN-H
CAN-L
CAN-H
CAN-L
CAN-H
GCP-30
Termination
resistor
GCP-30
GCP-MG
CAN-L
CAN-H
CAN-L
CAN-H
CAN_L
GND
CAN_H
Shield
resistor
GCP-30
Termination
Figure3.1:CAN bus topology
Wiring the RS-485 Modbus interface
The RS-485 Modbus interface is used for integrating the GCP-MG into a two-wire Modbus
over Serial Line network. The use of the RS-485 interface must be configured using the
web interface (See the section called “Configuring serial line Modbus”). The GCP-MG is
a Modbus slave device.
1The number of logically adressable units may be less.

Installation
UMGCPMG-2201 13
The RS-485 signals are located at the 3.81 mm 6-pin pluggable terminal block on the top
side of the mounted unit (refer to Figure2.1, “Location of connectors”). The following
table and picture shows the pinout:
GND
D-
D+
RS-485

Pin Signal Function
3 GND Modbus Common
4 D+ Modbus D1
5 D- Modbus D0
6 reserved, must be left unconnected
7 reserved, must be left unconnected
8 reserved, must be left unconnected
Table 3.3: RS-485 connector pinout
• Line termination is required and is typically done with a 120 Ohm 1/4 W resistor. For
RS-485 operation the bus must be terminated at both ends.
• Maximum number of RS-485 nodes without repeater is 32.
• Stub connections off the main line should be avoided if possible or at least be kept as
short as possible. Stub connections must not have terminating resistors.
• Maximum cable length to 1200 m (4000 ft).
• To assure a high degree of electromagnetic compatibility and surge protection the
cable should be twisted pairs and shielded. An additional cable conductor or pair may
be used for the GND reference.
Do not connect the cable shield to the GND pins! Use an external chassis ground
connection to terminate the shield.
Wiring the RS-232 Modbus interface
The RS-232 Modbus interface can alternativly be used for serial communication to a
Modbus master device instead of RS-485. The use of the RS-232 interface must be
configured using the web interface (See the section called “Configuring serial line
Modbus”). The GCP-MG is a Modbus slave device.
The RS-232 Modbus connector is a male 9-pin D-sub type located at the bottom side of
the mounted unit (refer to Figure2.1, “Location of connectors”). It has industry standard

14 UMGCPMG-2201
EIA-574 data terminal equipment (DTE) pinout as shown in the following table and
picture:
GND TDX
CTS DTR
RI
RXD
RTS
1
6
CD
DSR
Pin Signal Function Direction
1 DCD (unused) in
2 RXD Receive data in
3 TXD Transmit data out
4 DTR (unused) out
5 GND Signal ground
6 DSR (unused) in
7 RTS (unused) out
8 CTS (unused) in
9 RI (unused) in
Table 3.4: RS-232 Modbus connector pinout
• Maximum cable length is 15 m (50 ft) or a length equal to a line capacitance of 2500
pF, both at the maximum standard bit rate of 20 kbps. If operating at higher bit rates
the maximum cable length drops to 3 m (10 ft) at a bit rate of 57.6 kbps.
• To assure a high degree of electromagnetic compatibility and surge protection the
RS-232 cable should shielded. The shield shall be connected to an external chassis
ground at the either or both ends, depending on the application.
• The shield must not be connected to the GND pin.
To connect the GCP-MG to a PC (Personal Computer) or any other device with data
terminal equipment (DTE) pinout you need a null-modem or cross-over cable.
Connecting Ethernet
The following table describes the 10BASE-T Ethernet RJ-45 connector pinout:
TX+
TX-
RX- RX+
1
Pin Signal Function
1 TX+ Non-inverting transmit signal
2 TX- Inverting transmit signal
3 RX+ Non-inverting receive signal
4 Internal termination network
5 Internal termination network
6 RX- Inverting receive signal
7 Internal termination network
8 Internal termination network
Table 3.5: Ethernet connector pinout
• We recommend to use Category 5 UTP network cable.
• Maximum cable length is 100 m (3000 ft).