J1939 Gateway

Version 2.00 Installation and Operation Guide

5527 Louetta Road Suite D Spring, Texas 77379 Tel: (281) 350-8751 sales@MONICOINC.com www.MONICOINC.com

MONICO, INC.

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Table of Contents
Introduction ............................................................................................................................................................ 3

Section 1: Power Supply ........................................................................................................................................ 4

Section 2: Hardware Installation ........................................................................................................................... 7

Section 3: CANbus Connection .............................................................................................................................. 8

Section 4: J1939 Gateway Host Connections .................................................................................................... 9

Section 5: Troubleshooting LEDs ...................................................................................................................... 11

Section 6: MonicoView II Programmer........................................................................................................... 12

Section 7: Active Diagnostic and Previously Active Diagnostic Codes .............................................................. 20

Section 8: J1939 Setup File Structure.................................................................................................................. 22

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Introduction
The J1939 Gateway is a completely new generation of communications interface from Monico. It resides on a Primary CANbus network and acts as a communications gateway between industrial engines that use S.A.E. J1939 protocol and other common protocols and networks. In the case of the EMCP3 series of generators, it resides on the PRIMARY CAN1 link. The J1939 Gateway is a pre-configured solution that automatically receives broadcast PGNs and parses out the individual SPNs from the network. All 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 which is available for download on our website at www.monicoinc.com/support . Make sure to check the website for the latest software revisions before installation. The major features are listed below: The J1939 Gateway-Modbus Version offers Modbus RTU over Serial RS-232 and RS-485 as well as Modbus TCP/IP over Ethernet. All ports are available on the same unit The J1939 Gateway uses MonicoView II software as a User Interface via a USB connection that allows you to configure the ports and see exactly which parameters are responding on your installation. The J1939 Gateway has an integral 24 VDC Power Supply The J1939 Gateway is designed to be mounted on Din-Rails, so no adapters are needed The J1939 Gateway uses modular jacks for connections to the host ports which minimizes wiring errors, especially when using our optional factory cables The J1939 Gateway allows for other host protocols such as BACnet and can push parameters directly to Allen Bradley Data Registers or Controller Tags, GE Fanuc Analog Input Registers, and Siemens Data Blocks via RS-232, RS-485, and Ethernet. Special instructions for these versions are covered in the appendix sections of this manual.

As always, you can count on Monicos No Questions Asked support policy. We are committed to timely support of every customer who contacts us for help regardless of where the Monico gateway was purchased. The only thing that matters to Monico is a successful installation. The J1939 Gateway PLUS adds considerable functions including: Real-time data logging on 2 GB Compact Flash Card Email alerts with specific text descriptions of all available Diagnostic Codes SNMP Traps for each Diagnostic Code-SNMP Version only Color touch screen HMI for viewing live data and diagnostic code descriptions Custom HTML web server Sync server/FTP Client to manage log files If you need these IP functions, please contact the factory to upgrade your hardware.

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Figure 1.0 Gateway Connections Overview

Section 1: Power Supply

The J1939 Gateway requires regulated 24 Vdc +/- 10% with 1000 ma power maximum. Must use Class 2 or SELV rated power supply. You may use either an Isolated power supply, or the properly grounded engine batteries to power the Gateway. If 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.

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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.

If you must use 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 Gateways power supply should be at least 22-gage wire. If a longer cable run is used, a 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 with a Class 2 or SELV rating is to be used. 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.

EMC INSTALLATION GUIDELINES

Although the J1939 Gateway is 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. 1. 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. 2. The unit should be mounted in a metal enclosure, which is properly connected to protective earth. 3. 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. a. Connect the shield to earth ground (protective earth) at one end where the unit is mounted. b. Connect the shield to earth ground at both ends of the cable, usually when the noise source frequency is over 1 MHz. c. Connect the shield to common of the Data Station and leave the other end of the shield unconnected and insulated from earth ground. 4. 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 -5-

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Control cables within an enclosure should be routed as far away as possible from contactors, control relays, transformers, and other noisy components. 5. Long cable runs are more susceptible to EMI pickup than short cable runs. Therefore, keep cable runs as short as possible. 6. 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: Fair-Rite part number 0443167251 (RLC part number FCOR0000) TDK part number ZCAT3035-1330A Steward part number 28B2029-0A0 Line Filters for input power cables: Schaffner part number FN610-1/07 (RLC part number LFIL0000) Schaffner part number FN670-1.8/07 Corcom part number 1 VR3

SPECIFICATIONS
1. POWER: 24 VDC 10% 200 mA min., without expansion card 1 Amp maximum with expansion card fitted Must use Class 2 or SELV rated power supply. 2. COMMUNICATIONS: USB/PG Port: Adheres to USB specification 1.1. Device only using Type B connection. Serial Ports: Format and Baud Rates for each port are individually software programmable up to 115,200 baud. RS232/PG Port: RS232 port via RJ12 COMMS Ports: RS422/485 port via RJ45, and RS232 port via RJ12 DH485 TXEN: Transmit enable; open collector, VOH = 15 VDC, VOL = 0.5 V @ 25 mA max. Ethernet Port: 10 BASE-T / 100 BASE-TX RJ45 jack is wired as a NIC (Network Interface Card). 3. LEDs: STS Status LED indicates condition of Data Station. TX/RX Transmit/Receive LEDs show serial activity. Ethernet Link and activity LEDs. CF CompactFlash LED indicates card status and read/write activity 4. MEMORY: On-board User Memory: 4 Mbytes of non-volatile Flash memory. On-board SDRAM: DSPSX: 2 Mbytes DSPGT: 8 Mbytes Memory Card: CompactFlash Type II slot for Type I and Type II cards. 5. REAL-TIME CLOCK: Typical accuracy is less than one minute per month drift. Crimson 2.0s SNTP facility allows synchronization with external servers. Battery: Lithium Coin Cell. Typical lifetime of 10 years at 25 C. A Battery Low system variable is available so that the programmer can choose specific action(s) to occur when the battery voltage drops below its nominal voltage. 6. ENVIRONMENTAL CONDITIONS: Operating Temperature Range: 0 to 50C Storage Temperature Range: -30 to +70C Operating and Storage Humidity: 80% max relative humidity, non-condensing, from 0 to 50C Vibration According to IEC 68-2-6: 5 to 150 Hz, in X, Y, Z direction for 1.5 hours, 2 gs. Shock According to IEC 68-2-27: Operational 30 g, 11 msec in 3 directions. Altitude: Up to 2000 meters 7. CONSTRUCTION: Case body is burgundy high impact plastic and stainless steel. Installation Category I, Pollution Degree 2. 8. POWER CONNECTION: Removable wire clamp screw terminal block. Wire Gage Capacity: 24 AWG to 12 AWG Torque: 4.45 to 5.34 in/lb (0.5 to 0.6 N-m) 9. MOUNTING: Snaps onto standard DIN style top hat (T) profile mounting rails according to EN50022 -35 x 7.5 and -35 x 15. 10. CERTIFICATIONS AND COMPLIANCES:

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SAFETY C-UL Class I Division II Groups A-D Approved for Hazardous Locations UL Listed, File #E317425, ANSI/ISA12.12.01-2007, CSA22.2 No. 213-M1987 LISTED by Und. Lab. Inc. to U.S. and Canadian safety standards UL Listed, File #E302106, UL508, CSA 22.2 No. 14-M05 LISTED by Und. Lab. Inc. to U.S. and Canadian safety standards IEC 61010-1, EN 61010-1: Safety requirements for electrical equipment for measurement, control, and laboratory use, Part 1. ELECTROMAGNETIC COMPATIBILITY Emissions and Immunity to EN 61326: Electrical Equipment for Measurement, Control and Laboratory use. Notes: 1. Criterion A: Normal operation within specified limits. 2. This device was designed for installation in an enclosure. To avoid electrostatic discharge to the unit in environments with static levels above 4 kV precautions should be taken when the device is mounted outside an enclosure. When working in an enclosure (ex. making adjustments, setting jumpers etc.) typical anti-static precautions should be observed before touching the unit. 11. WEIGHT: 15.1 oz (456.4 g) Immunity to Industrial Locations: Electrostatic discharge EN 61000-4-2 Criterion A 2 4 kV contact discharge 8 kV air discharge Electromagnetic RF fields EN 61000-4-3 Criterion A 10 V/m Fast transients (burst) EN 61000-4-4 Criterion A 2 kV power 2 kV signal Surge EN 61000-4-5 Criterion A 1kV L-L,2 kV L&N-E power RF conducted interference EN 61000-4-6 Criterion A 3 V/rms Emissions: Emissions EN 55011 Class A

Section 2: Hardware Installation

DIN rail should be mounted horizontally so that the units ventilation holes are vertical in relation to cabinet orientation. A minimum clearance of 1 inch (25.4 mm) should be maintained above and below the unit in order to ensure proper thermal regulation.

Figure 2.1 Hardware Installation -7-

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Figure 2.2 Hardware Dimensions

Section 3: CANbus Connection

Connection to the CANbus Network is via the removable terminal block (Figure 3.1). The two-color LED RUN/ERR will be RED when there is not a J1939 network attached and will be Green if the connection is active. IF you do not have a green light, then you are wired incorrectly or the baud rate is not set correctly. The vast majority of J1939 Networks will be at 250 kbaud.

Figure 3.1 CANbus Connection -8-

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Section 4: J1939 Gateway Host Connections

The Host device (PLC, HMI, Building Management System, etc.) is connected to the Gateway through one of three host ports. The Gateway offers one RS 232 port (RJ-11 Jack); one RS-485 port (RJ-45 Jack) and one Ethernet Port (RJ-45 Jack-Shielded).

Host Connection-RS-232 via RJ-11 Jack

Figure 4.2 RS-232 Connections

Host Connections-RS-485/RS-422 via RJ-45 Jack

Figure 4.3 RS-485/RS-422 Connections

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Figure 4.3 RS-485/RS-422 Schematic Please note that different companies use different terminology. For example, some use TxA and TxB to describe 2- wire RS-485 connections. Some use Tx+ and Tx-. In general. TxA=Tx- and TxB=Tx+ For 2-wire RS-485, use Pin#7 = (+) and Pin#8 = (-). Alternatively, 1 & 8 or 2 & 7 or 1 & 2 may also be used. DO NOT JUMPER 1 & 7 OR 2 & 8 AS THIS IS ALREADY DONE INTERNALLY.

Host Connections-TCP/IP over Ethernet via RJ-45 Shielded Jack

Ethernet

Figure 4.4 Ethernet Connections

ETHERNET COMMUNICATIONS

Ethernet communications can be established at either 10 BASE-T or 100 BASE-TX. The Gateways RJ45 jack (Figure 4.4) 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 192.168.1.20
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Section 5: 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
LED Rapidly Flashing Steady Indication Gateway is currently loading program Gateway is operating normally

Table 5.1 STS LED

SERIAL HOST PORTS - TX/RX LEDS

LED Green Red Indication Transmitting Receiving Table 5.2 Serial Host Port LEDs

CAN PORT RUN/ERR LED

LED Green Red Indication CANbus connection good No CANbus connection Table 5.3 CDL Port LEDs

TCP/IP ETHERNET PORT LEDS

LED Yellow (Solid) Yellow (Flashing) Green Amber Indication Link Established Network Activity 10 BASE-T Communications 100 BASE-T Communications

Table 5.4 Ethernet Port LEDs

These LEDs are the first step in troubleshooting communications issues. Please note the action of these LEDs, IN DETAIL, when contacting the factory for technical support.

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Section 6: MonicoView II Programmer

The MonicoView II Programmer is a NEW and 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 use LINK-EXTRACT to save a copy of the original .mv2 file before making changes. If you click on the UPDATE button before OPENING a valid file or EXTRACTING the existing file, it will result in a blank file being downloaded to the Gateway which will render it inoperable. If this should occur, contact the factory and we can email a copy of the file supplied with the Gateway. Please make note of the Version Number on the label on the right side of the Gateway, so we can identify the appropriate file. When upgrading MonicoView II Programmer versions, us the REPAIR option. The connection is established through a standard USB device cable that has the rectangular connector on one end and the square connector with two rounded edges on the other. Make sure to click on LINK-OPTIONS and set the connection to USB.

Installing USB Drivers

In some cases, connecting a laptop to AC can cause electrical grounding issues. In some situations, a grounded AC supply on a laptop can cause intermittent errors with the laptop USB port. Each time you connect, using the MonicoView II Software, to a new CDL Gateway unit, you will see the Windows Found New Hardware screen. Make sure to plug in the USB Cable when the Gateway is powered down. Upon power up, it will then ask for both required drivers to be installed at once.

First Installation
In most cases, the USB driver installation will be automatic and you will not notice any issues. However, on older units or under certain circumstances, the first installation of the USB drivers from a specific computer will have to be done manually. After this first installation, on a given PC, it will know where to look for the appropriate files. When asked 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 6.1 below and the Install Automatically should be selected by default. INSTEAD, choose Install From List or Specific Location, click NEXT and use the Browse button to select the following location: C:\Program Files(x86)\Monico\MonicoView II\Device
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Click Next and follow the instructions below to finish the process. From this point on, you can use the Automatic Install option which is much simpler.

Subsequent Installations
When asked 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 6.1 below and the Install Automatically should be selected by default. If your first installation is not successful, you will need to follow the instructions at the end of this section to navigate to Device Manager and perform a manual install.

Figure 6.1: USB Driver Automatic Installation After this screen you will 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 6.2: Windows Compatibility Warning

Click Finish when this screen is done. There may be 2-3 drivers that will need to be loaded depending on the model, but it will not be found until you download the program to the J1939 Gateway. After the initial installation or update of the J1939 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. NOTE: If your Operating System does not successfully install the drivers, you will need to perform this function manually. Go to Start and right-click on My Computer and choose Manage. Then click on Device Manager and look for any yellow ! beside any USB Devices. Right-click on the item and select Update Driver. Select Manual Installation this time and when you are asked to specify the location of the drivers, you will choose C:\Program Files\Monico\MonicoviewII\Device where the drive letter is the drive you selected when installing the software. This should correct the problem and this issue should not happen again. This only seems to happen the first time Windows attempts to install the first USB driver on a new PC. If this problem occurs, it is probably because of laptop USB port issues. Therefore, before following these instructions, disconnect the Gateway from the USB port, disconnect the laptop from AC Power, reboot the PC, and power cycle the Gateway.

Enabling TCP/IP Download Any function accomplished through the USB port can also be performed over an Ethernet Network with the exception of Firmware Upgrades. A compact Flash card installed in the Gateway is required to Upgrade Firmware over TCP/IP. However, you must first use the USB connections to enable IP DOWNLOAD under the REMOTE UPDATE section of the Ethernet port. Then you must go to LINK-OPTIONS and choose TCP/IP and enter the IP address of the J1939 Gateway. From this point you can perform database updates and port setting changes over the LAN. Deleting Unwanted Parameters When you expand a Block, you will see what parameters are assigned to each register. You can delete any parameters you will not be using. However, if you highlight a register and press the delete button on your keyboard it will remove this parameter. Make sure to save an original copy of the program and make changes to the file using another name. After making these changes, you must choose Link>Update to send the changes to the J1939 Gateway. This is the case with any subsequent changes.

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Adjusting Port Settings

The J1939 Gateway has several HOST PORTS including two RS-232 ports, an RS-485 port, and an Ethernet port. MonicoView II can be used to adjust the settings for any of these ports and to disable the ports that are not being used. For example, if you need to change the port settings for the RS-232 port you would see:

Figure 6.3: Serial Port Communications Settings To change any of the settings shown in Figure 6.3, highlight the value and enter the new setting and press enter to record the change. If the value is in a drop down window, just select the new settings. Notice that you can set a Drop Number. This allows you to use the RS-232 port with a multi-drop network using RS-232 to RS-485 converters. Enter the Device Address for the J1939 Gateway (in the case of Slave protocols) in the Drop Number box and press ENTER. If the port is setup as a Master Device, then the target drop number will be entered. The only difference with the RS-485 port is choosing whether you want 2-wire RS-485 or 4wire RS-485 or RS-422. This screen is shown in Figure 6.4 below.

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Figure 6.4: RS-485 Serial Port Settings

Settings for the Ethernet port are show in Figure 6.5 and include setting the Port Mode where you set whether to Manually Configure the IP address, request an IP address from a DHCP server or use IEEE 802.3. Then enter the IP address if manually configured and the associated Network Mask and Gateway.

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Figure 6.5: TCP/IP Ethernet Port Settings

Disabling and Enabling Devices The J1939 Gateway is a standard product that ships pre-configured with all ports active and populated with a full array of values. You may want to disable the unused ports by selecting the port and unchecking the box under Device Settings labeled ENABLE DEVICE as shown in Figure 6.6 below. By disabling unused ports you will maximize the performance of the Gateway.

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Figure 6.6: Enable/Disable Devices

Viewing Live Data

MonicoView II can also be used to view live data for each data block. Highlight an individual data block and click the button labeled View Block. This will cause the software to connect to the J1939 Gateway and display the current data for each parameter.

Figure 6.7: View Data Blocks

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A table will appear that will show the data block, the parameter tag, and the value in that register in both Decimal and Hexadecimal. Alternatively, you can right-click on the block and choose View.

Figure 6.8: Live Block Viewer

Installing Program Updates

If you are sent a program update from the factory, you will need to install it using MonicoView II. First install MonicoView II, start the program, connect the J1939 Gateway via the USB port on the front while the Gateway is powered down. Then connect power and perform USB driver installation if this is the first time you have connected to this particular gateway. After the first driver installation is finished, go to the file sent to you by the factory and double-click on it. This will automatically start MonicoView II. Select Link and then Send. This will begin the download process. During this installation, you may be asked to go through another USB Driver installation as shown above. Then MonicoView II will automatically finish loading the upgraded program. REMEMBER, IF THIS IS THE FIRST USB DRIVER INSTALLATION ON A PARTICULAR COMPUTER, YOU MUST USE THE MANUAL INSTALLATION METHOD OUTLINED IN THE BEGINNING OF SECTION 6.

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Section 7: Active Diagnostic and Previously Active Diagnostic Codes

The S.A.E. J1939 standard defines DM1 codes as Active Diagnostic Codes. An Active Diagnostic Code consists of an SPN (Suspect Parameter Number), an FMI (Fault Mode Indicator), and the number of Occurrences. The SPN indicates which device or sensor has the fault, the FMI provides details as to the nature and severity of the fault. The standard also defines DM2 codes as Previously Active Diagnostic Codes, or historical codes. In the J1939 Gateway, we use integer variable tags for each of the three diagnostic code parameters as shown in figure 7.1 below.

Figure 7.1 Collect Fault Data By default, we look at the five most recent Active Diagnostic Codes.

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In figure 7.2 below, you can see a similar block for the other ECM in this particular application. Each ECM on the network will have its own DM1 and DM2 codes.

Figure 7.2 Diagnostic Code Data Block

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Section 8: J1939 Setup File Structure

Each ECM on the network must be added and the Source ID entered. Each J1939 PGN (Parameter Group Number) must be programmed into its own block. Each PGN consists of multiple SPNs. In figure 8.1 you will see an example of a two ECM generator application that includes a GSC (Generator Set Controller) and an Engine ECM. Unlike other protocols the Gateway accepts, you have to enter data blocks under the CAN Interface J1939 in order to communicate. In other protocols, you create the master device and then put the blocks under the destination port only. In the J1939 Gateway, you must have each PGNs assigned to specific data block under the CAN INTERFACE J1939 which then has to be assigned to an Integer Variable Tag. Then the variable tag can be used in other parts of the communications section, the Operator Interface, Data Logger, or in Formula tags to perform math functions.

Figure 8.1 Device Setup File

Figure 8.2 shows the setup screen for the J1939 Gateway CANbus Source address. This address must be unique to the network. The baud rate will almost always be 250 kbaud, although we do support from 10 kbaud to 1Mbaud.
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Figure 8.2 J1939 Gateway Source Address Setup

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Figure 8.3 shows the setup page for the source address of the first ECM in this example. S.A.E. specifies certain ranges for each type of device, but some devices, such as this one, do not fit into that range. You can also uncheck the ENABLE DEVICE box to disable this ECM

Figure 8.3 ECM 1 Device Address Setup

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Figure 8.4 ECM 2 Device Address Setup You will notice in figure 8.4 that the universal source address for Engine #1 is zero. This number is also used for the first ECM, whether used on an engine or not.

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Manufacturers Proprietary PGNs

The J1939 Gateway Supports Manufacturers Proprietary A and Proprietary B PGNs. The first step is to highlight the CAN Interface J1939 and click on the button titled Add Additional Device. This will create a new device which you can name by simply highlighting it and typing in a new name. After entering a new name, you will need to enter a Drop Number, or Device Address which will be supplied by the manufacturer.

Proprietary PGN Setup

To create a custom PGN, highlight the CAN INTERFACE J1939. On the right side of the screen shown in figure 8.6 below, click on the MANAGE button.

Figure 8.7 Manage User Custom PGNs

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A Custom PGN setup screen will appear as shown in Figure 8.8 below.

Figure 8.8 Manage User Custom PGNs Click on Add/Edit PGN and enter the necessary information and again click on Add/Edit PGN. Then you will need to map this custom PGN to a new block in the Communications section and
assign integer variable tags to contain the data.

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