Table of Contents Information Section ‘Acronym Definitions. Foreword Literature Information Safety Description ang Function of the Customer Communication Mocs, . Safety Section Important Safety Information Operation Section ‘Display Description . Display at Power-Up Installation Section General Information Specifications Environmental Mounting... COM Battery (internal) . Wiring Connections and Battery Power General Wiring Connections . COM Data Link Guidelines General Wire ang Cable Specifications RS-2820 Cable Requirements Programming the Engine Number. ‘Communication Initialization Direct Connection Initialization Remote (Modem) Connection Initialization Maintenance Section Troubleshooting. COM Error Code Troubleshooting ‘Aatitional System Troubleshooting MBX Communication Troubleshooting Determining Programmed Cormmunication Parameters in CCM Replacing the COM Battery CCM Customized Systems Section S-282C Communication Protocol for Customized Systeme Standard Preamble MBX Message Checksums. PID Security Levels. Logging In to the CCM Instruction identiiors (IID) Fault Identifiers (FID) Parameter Identifiers (PID) for COM (MID $61) 02 02 02 2 2 04 1 Table of Contents Information Secti Customized Systems Section for EMCP Ii Systems RS-232C Communication Protocol for Customized EMOP il Systems PID Secunty Levels, Parameter \Gentifiers (PID) for EMCP Il (MID $58 -85F) Customized Systems Section for 3500B Systems RS-232 Communication Pratocol for Customized 35008 Systems PID Seouiity Levels Parameter identifiers (PID) for 28008 EC's, (MID $21-26, $28-829) M5X Example Section MBX Communication Protocol Programming Examples woes Create a Broadcast List Create a Broadcast List (ID 13) Status Reply (IID 15) Aotivate a Broadcast List (lID 11) Status Reply (IID 15) Broadcast Response (iD 10) Deactivate 2 Broadcast List (ID 12) Status Reply (ID 15) Reading Faun from EMOP Il GSC Single Parameter Read Request [iD 24). . Single Parameter Read Response (IID 25) Special Parameter Command (ID 00) Single Parameter Read Response (IID 25) Monitoring Generator Phase... Single Parameter Write Request (IID 34) Single Parameter Write Response (IID 35) ion 33 33 33 50 RRFRRLLLLKS2 ADEM com cD cis DCE OTE DTR ECM ECs EIP EMCP EMURFI ‘Acronym Definitions Information Section Acronym Definitions Advanced Diesel Engine Managerrent Customer Communication Module Component Identifier Clear To Send Data Communication Equipment Data Terminal Equipment Data Terminal Ready Electronic Control Module Engine Control Switch Electronic instrument Panel Electronic Modular Control Panel Electro-Magnetic Interference! Radio-Freauenoy Interierence Electric Power Generation Electronic Technician Electronic Unit Injector Fuse Fault Identifier Generator Set Control instruction Identifier Least Significant Byte Module identifier Most Significant Byte Mechanical Unit Injector Personal Computer Parameter \dentifier Programmable Logie Controller Request To Send Foreword Literature Information This manual contains safety, installation operation, and troubleshooting information for the Customer Communication Module (CCM). Read, study, and keep this manual with the other product literature. Continuing improvement and advancement of product design may have caused changes to the Customer Communication Module which are not included in this manual. Whenever a Question arises regarding this manual, please contact your Caterpillar dealer for the latest available information ‘Additional information van also be found in the following literature for CCM PC sotware. JERD2157, JERD2162 (Windows version manual and software) NOTE: All references in this manual to EMCP II apply to EMCP Il, EMCP II+, and EMCP II+P unless otherwise stated. All references to EMCP II also apply to EMCP |I+P unless otherwise stated. These rules similarty apply to | GSC, GSC+, and GSC#P, NOTE: All references in this manual io 3500B EU! Engines also apply to 3500 with EUI option engines. Safety The safety section lists basic safety precautions. Read and understand the basic precautions listed in the safety section and throughout this manual before installing or operating this product.Description and Function of the Customer Communication Module ‘The Custorner Communication Module (CCM) provides a two-way communication link Between the electronic controlar (GSC or FCM) and a host device. The operator of the host device is able fo remotely contral, monitor, 9" program the engine equipped with electronic engine control in much the same way an operator does from the panel (35008 Marine application does not allow remote control capabilities) ‘The host device can connect directly to the CCM ‘oF remotely, by means of two modems. The host device can be a personal computer (PC), Programmable Logic Contralier (PLC), or any ‘other device with a RS-232C pot, CCM Compatible software is available from Caterpillar Inc. for use with a PC (refer to the Caterpillar CCM PC For Windows: Gettng Started Manual, included with the sottware package, for more information on the PC sohware). The CCM can also be used with customized software, and the serial data format is provides, allowing the user to program their device to communicate with the COM. Refer to the RS-222C MEX ‘Communication Protocol! and the Parameter ‘entifiers (PID) sections for adaftional information, —arreuuan ‘CATERPILLAR ‘Customer Commurication Module (iron and rear view) ; cei | Each CCM is serialized. On the bottom of one flange is a5 digit number preceded by the letters “SN*. The Caterpillar part number is located an the same flange, and is @ 7 digit number (XXX-XXXX). COM System Connection. See installation section ofthis ‘manual for complete configuration options, (1) Electronic Engine Controller. (2) Junction boxes. (8) COM. (4) Optional modems. (6) Hast computer. (6) Phone connection,Important Saiety information Safety Section Important Safety Information Most accidents involving product operation, maintenance and repair, are caused by failure to observe asic safety rules or precautions. An accident can oflen 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 to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury of death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation. lubrication, maintenance and repair information. Salety precautions and wamings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. The hazards are identified by the "Safety Alert Symbol" and followed by a “Signal Word" such as "WARNING’, as shawe below. Peay The meaning of this Safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning, explaining the hazard, can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on the product and in this publication. Caterpillar cannot anticipate every possible citcumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not ail inclusive. If a tool, procedure, work method or operating technique not specifically recommended by Caterpillar is used, you must satisty yourself that itis safe for you and others. You should also ensure that the product will not be damaged or made unsale by the operation, lubrication, maintenance or repair procedures you choose. ‘The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time, These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.’ Display Description During normal operation, the CCM display shows the status of the data link and RS-232C activity, 28 well as some of the current communication parameters 5 Display Description Operation Section Dispiay at Power-Up During the power-up sequence, the CCM display undergoes a lamp test (8.8.8.), followed by the communication protocol parameters (n61 9600 £00) that have been programmed into it. ‘An example of the pows be -up sequence would ‘BBB. ABI 9600 E00 €.3.0. ‘BSE. | Alleegments turned on for wo second lam test | No party (deteut vaive) ht data bts (detaut value) ‘One stop it (detaut valve) 2 (Getaut value i 5 6 Description of Display Characters (1) Error code. (2) CAT Data Link activity. (3) First digit of error code. (4) RS-232C transmit by COM. (6) Second digit of error code. (6) FS-232C receive by CoM. The values " and 0" indicate an error code of "00" that means no faults are present, and the CCM is in normal operating mode. The complete jist of error codes are in the Troubleshooting section. The periods on the aisplay may be either flashing or steady to indicate activity on the CAT Data Link or RS-232C pon. No period indicates that no activity is taking piece NOTE: For the older CCM (Caterpillar part number 117-6170), the logged faults will appear on the CCM display every 60 seconds, each for 2 seconds. This flashing fauit log will not appear for any other version of CCM. This log can be cleared using the CCM PC software. ing no faut are present Refer to the Caterpillar CCM PC For Windows. Getiing Started Manual far more information on changing the communication values. It is important that these communication values match those for the modems (if used} and the host device.6 General information Installation Section General Information When @ CCM is installed, these requirements must be met * The environmental, mounting, wiring, and cable specttications mist be met * The connection diagrams must be followed. « Itis possible to use modems to increase the communication distance between the host PC and the CCM. It is the user's responsibility to provide and properly set up the modems. Specifications Environmental * The ambient operating temperature range is from -40° to +70°C ( ~40° to 158°F) # The storage ternperature is from ~40° to ++85°C (-40° to 185°F) + The unit must be protected from direct contact with liquids (splash-proof). If sealing of the unit is required, the CCM must be in a ‘water-tight enclosure. Mounting The CCM can be located on a desk or shelf The rubber feet on the bottom of the CCM can also be Ternoved to allow panel mounting NOTE: Do not mount the CCMon the engine, or within the engine mounted instrument panel. It iS not designed for this environment CCM Battery (Internal) The CCM contains a battery that supplies power for internal memory whenever the CCM power is turned off. For adaltional information, refer to the "Replacing the CCM Battery" section COM Mounting Dimensions ‘EGU MOUNTING DIMENSIONS ‘35mm (14m) 1085 mim (6.19 1), 78.0 mm (2.87 in) 7S mim (.29 1) claretee hale (2) 7800 mm (5.12) 149.0 mm (STH) 662mm 261) $255 rem (494m) 178mm (70) Wiring Connections and Battery Power + The Battery voltage input requirements are from 15 to 48 volts DC (24 or 82 volt DC nominal power). + B+/- power dissipation is approximately 3.0 watts at 24 volts. ‘+ Multiole engines rnust share common ground (B-). + Multiple engines must use diodes to prevent power-sharing between units, See “CCM Wiring Connections for Multiple Gensete™ Giagram on following page. When multiple units are to be connected to the CCM, junction boxes must be installed as shown in the following illustration. This allows any engine to be disconnected for service or Taintenance without power interruption to the CCM and the other engines.—_—_—_—_—_——SESEE 7 Specifications Installation Section , General Wiring Connections SHIELD | ) i | } f — pans | 4 i | wae (tt | | * | | | | | 4 | 4 i | on t | ver | | us | CGM Wiring Connections for Mulipe Gensets (1) dunetion box for Unit 2. (2) Junction box for Unit 1. (3) COM, NOTE A: Shield should be ground in one ication only, as nea a8 pessioe to battery negative NOTE 8: Diode is only necessary wnen connecting multiple genges. NOTE ©: Battery postive and negative are to be taken trom the EMGP I (f equipped) ar from the 24 pin customer connect leeated on the bottom of the Electron instrument Panel (EIP).8 Specifications Installation Section CCM/Data Link Guidelines The CCM has the ability to communicate with up to eight other controllers. The number of connections available depends on the type of Gevice to be connected. For genset applications up to eight controllers can be connected to the CCM. Marine applications are limited to a maximum of three connections. The CCM identifies different controllers on the data link by their Module Identifier (MID). The MID's, in some cases, are programmable. Refer to the Programming the Engine Number section in this manual for more detailed information on programming the MID’s. Each controller connected to the CCM must have a unique MID. There are two versions of ECM's for 35008 EU! Engines. To properly understand CCM/data link connections for 35008 EU! Engines, itis necessary to know the version of the engine's ECM. The version of the ECM is based on the serial number of the engine as listed on the engine nameplate. Use the following chart to determine theycorrect version of controtier for each engine. ‘Serial Numbers jon D Tnwo0001 & Up 2 W000! & DWO0001 & Up ‘4AnN00001 Up 212 & Up 73100077 & Up 1001446 UB) eXNO0%456 UP ‘981002008 Us ‘BANOOI21 8 UP {ganoao57 te ero 196 'GANOOODT to @ANO0720 Version C of the ADEM I! controlier (ECM) has a primary data link for use with the CCM This data link is called the CAT Data Link The MID of this controller, on the CAT Data Link, is a fixed value. Because each controller must have @ unique MID 2s mentioned previously, the CCM can only be connected to one Version C ECM on the CAT Data Link. Version D of the ADEM II controller (ECM) has the same primary data link as Version © (CAT Data Link) with a fixed MID value. In acition Version D also has a secondary data link (Secondary CAT Data Link) for use with the CCM. The Secondary CAT Data Link has a programmable MID value (up to eight cifferent values for genset applications. three cifferent values for marine applications) EMCP II (basic model) has a primary data link for use with the CCM. This data link is calied the CAT Data Link and has a programmable MID value (up to eight different values). MCP I+ has the same primary data link as EMCP Il (CAT Data Link) with a programmable MiD value. In addition the MCP I+ also has @ secondary data link (CCM Data Link) for use with the CCM. The COM Data Link has a programmable MID value (up to eight different vaiues). Although the terminology differs between 35008 Version: D anc EMCP i+ applications, the Secondary CAT Data Link and CCM Data Link, respectively, can be treated in the same manner. There is a maximum of one CCM per data link. There is a maximum of one CCM per engine.eT ie Specifications Installation Section ‘The previous electronic controller descriptions € » govern haw the devices can be connected to the CGM. When an ADEM Il controller (Version C or D) is connected with an EMCP Ni (or EMP II+) controller, the CAT Data Link is always used for the connection between the two controllers. All supsequent connections to the CCM (ADEM II Version D or EMCP I+) are made using the secondary data link. The following examples wll illustrate some valid CCM connections with multiple electronic controllers. These examples are oniy a representation of most possible valid connections or combinations. There are many other valid combinations based on these examples Example 1- MUI Gensets witn EMCP II (Basic Model) —— EMOP 1 4 Date Link Genset #1 cm (CAT Data Lin MCP IT Genset 48 ee Example 2~ MUI Gensets with EMCP I+ I om Data Link CAT Oa Link Gnas LL car pata Link Gonset #1* 10 Specifications Installation Section r Example 8 - 35008 EU! Genset (Version C ECM) con CAT Data Link ADEMT Example 4 - 9500B EU! Gensets (Version D ECM) [=q ‘Secondary GAT Data Link Gens CAT Data Link- Example 5 - 95008 EU! Gensets (Versions C and D ECM) CAT Data Link Secon Note: For this application CAT bata Ln : cniy one Verson@ ECM is alowed CAT Data Link. Example 6 - $5098 EU! Genset (Version G ECM) with EMCP It (Basic Mod) Genset #1 CAT Data Link] ADEMT Genset #8. CAT Version C] Version 0| tet Gensel #6 Ewer Lata kink PADEMTL Version C ea CAT Data Link Gensel #1| i | | | 1" Specifications Instatlation Section Example 7 - 35008 EU! Gensets (Version C ECM) wih EMCP + aT ewer Dank CENT] Genset 67 CAT ep i] aa ek DET 4 Genset oa Example - 95008 EUI Gensets (Version D ECM) with EMCP TH+ ee ata Unk car | EncP no} Data Link ADEM com Data unk Version ket a_i + Secondary CAT 1 Daal CAT Eup To] Data Lok [ADEM EMOP Tey version DI Sense: #6 - 95008 EU! Gensets (Version D ECM) with EMGP I+ Ul Gensets (Version D ECM) with EMCi _ Secondary GAT Date Unte cow Data Li Evora Dal ine Data Link [ADEWTT com vce ne] oe TEE Genget tt Secondary, Note: For thi application cAY Oats Le ‘only four gensets can De COM connected (CCM limited Des Link to eight connestons), 1 Car fuer] Date Lnk genset Note: The two configurations shown in Examples 8 and 9 offer trade offs. In Example 6, eight gensets can be connected. However in Example 9, more detailed information can obtained from the ADEM 0 controlter However, in this configuration, only four gensets can be connected.12 Specifications Installation Section CoM Example 10 - 95008 EU! Marine Engine (Version © ECM) GAT Data Link Note: One CCMis required per ‘engine for Version © ECM, Example 11 - 3500B EU! Mesine Engine (Version D ECM) ‘Secondary CAT Data Link eg Data Link [Besae Engine #3, ADEM It Version D|AT General Wire and Cable Specifications The following specifications for wire and cable is given ta reduce voltage crops over long runs of wire and to reduce EMI/RFI interference. + Do not run data link wiring in the same raceway as high power cabling, such as generator leads, or any AC cabling + The wires connected to (+) B and (-} Bon the CCM must be at least 16 AWG. + Maximum CAT Data Link cable and (+/-) 8 wire length is 455 m (7500 ft), including wire runs between any multiple engines when a CCM is present. Otherwise, maximum wire length is 30.5 m (100 ft + Maxirnum total wire length for the RS-232C cable is 15 m (50 ft NOTE: in order to conform to the European Economic Community (EEC) 338 Directive, the RS-282 cable must be shielded. + No terminations or splices allowed on the above wires, except as noted in the connection diagrams. + Thé cable connected to (+{-) CAT Data Link must be 16 AWG, shielded twisted pair cable, Use 123-2376 Electric Cable, Belden 8719 Cable, or equivalent. NOTE: For 35008 additional wiring information, refer to SEHS9951, Customer Communication Module and Programmable Relay Controi Model installed on 25008 Engines with Electronic Instrument Panel. CAT DATA LK CRBS SPECIFICATIONS RESISTANCE | ‘AND CAPACITANCE | 740mQ - | - |e) | | eae | Bey | | “Cot = Coneacie: to conaucie © 1S = Conductor io shies SSOGR.= Single conauetor sens resistance (16,AWG, 18 Sverre 13 Specifications Installation Section RS-232C Cable Requirements The COM is classed as Data Terrninal Equipment (OTE) for RS-232C communication: + The COM RS-282C connector is a standard 25.pin D-shell connector with pins. + The RS-282C cable must be shielded + When connected to other DTE devices, such a8 personal computers, a Null Modem cable or adapter is required to connect the two devices + When the CCM is connected to Data Communication Equipment (DCE), such as modems, printers, or terminals, no Null Modem cable or adapter should be used. ee 5-226 PIN DEFINITIONS wee Description 2_| Data Transmit OX) [ [5 [Bae Receive (Fo 7_| Sreune a] 20__| Date Terminal Ready (OTA) =a ifthe CCM is connected directly to a PC with a 25-pin RS-232C connector, then a 25-t0-25 pin Cable is needed in adiition to the Null Madem adapter (refer to the following illustration with 25-pin connectors). lf the PC has a 9-pin RS-232C connecter it requires a 9-10-25 pin cable with a Null Modem adapter (refer to the following tiivstration with 9-pin connectors) The Null Modern adapter correctly connects the Data Transmit of one device to Data Receive of the othet and vice versa. It connects the Data Carrier Detect and Data Terminal Ready pins in a similar manner. Ready-made cables can be purchased from most personal computer suppliers. NOTE: Make sure thal the purchased cables and Null Modem adapters support ALL pin connections noted in the "RS-232C Pin Definitions’ chart above.1 Specifications Installation Section 3 / £ Tre $42 9x PK mbh—Sy > 9 RK Ground 5 > >£——Z > 7 Ground boot DCD oTR4 Pp» 4 25 > a0 oT [3 fo COM [Cable Requirements for Direct Connection io PO with 25-Pin Connector (1) PC with 25-pin RS-232C connector. (2) 25-10-25 pin female to male cable. (3) Null modem adapter. (4) COM with 25-pin RS-282C connector. prs Pred £0] ax grand? pee | 7 ean | THE P< 22 TK COM Gable Requirements for Modem Connecting to PC. with &-Pin Connector (1) PC with Spin RS-2320 connector. (2) 9-t0-25 pin female to male cable. (3) Modems connected by telephone lines. (4) 28-10-25 pin male to female cable. (6) COM with 26-pin RS-232C connector. (6) Telephone line. Tepe AX3 3 > —$_S > sax COM Cable Requirements for Direct Connection 1¢ PC with 8-Pin Connector {1) PC with &-pin RS-232C connector, (2) 810-25 pin female to male cable. (3) Null modem adapter. (4) COM witn 25-pin RS-232C connestor. If the CCM is to be used with modems, then. either 2 25-10-28 pin cable or 2 90-25 pin able is needed to connect to the modem depending on the number of pins on the 32C connector of the PC. NOTE: Null Modem adapters should not be used when connecting a modem to either the PC or the COM. } Ground 7 7 Ground cps b> ieee pcp pa 20 j-> 2020 >| so TA, eee [tee pe ea olan one ip Eo rows L_pTa 20 2ooTr | COM Gable Requirements for Modem Connecting to PC with 25-Pin Connector (1) PC with 26-pin RS-232C connector. (2) 25-40-25 pin femaie to male cable. (8) Modems connected by telephone lings. (4) 25-10-25 pin male to female cable, (8) COM with 25-pin RS-232C connector, (6) Telephone Tine.Programming the Engine Number The electronic controller of each engine must be programmed with the correct engine number to identify them to the CCM. The electronic controller is programmed to Engine Number 1 at the factory. Installations with one genset per CCM will normally leave the electronic controller engine number programmed to number one. Refer to CCH/Data Link Guidelines section for details ‘on which controllers are programmable. To change the engine number of the electronic controller, follow these steps: For EMCP Il Applications 1, Refer to the topic Engine Setpoints - OPS in the Systems Operation section of the appropriate EMCP Il or EMCP Il+ Service Manual. Follow the procedure for adjusting setpoints. The setpoint number is P22 - GSC Engine Number. The default value is 1, Corresponding to Engine Number 1 2. Following the procedure in the EMCP Il manual, change the value of P22 - GSC to the Gesirad value. The range of possible values are 1 through 8, corresponding to the engine number. Each unit connected on the same data link must have a unique number (MID) 3. Power cycle the GSC. For 3500B Applications 1. Using the Electronic Technician (ET) service tool, go to the Service pull-down menu. and select Configuration 2. Change the Secondary CAT Data Link Identifier configuration parameter (Cat Data-Link #2) to the desired value. NOTE: The Windows version of CCM PC software detects all electronic engine controllers and programs the PC with the correct unit adaresses, 18 Communication initialization Installation Section Communication Initialization The CCM may be connected directly or remotely (by means of modems) to the host computer. The initialization procedure differs depending on the type of connection and is necessary to ensure proper communication between the CCM and the host computer. When modems are installed between the CCM and the host computer, the complexity of the communication network is increased (refer to the *CCM/Host Computer Remote Connection With Modems’ illustration). The RS-232C ports of the host computer, the modems, and the CCM must be set to the proper communication parameters. In addition, the phone line ports of the modems must be compatible, To connect the modems, consult the manufacturer's instructions. Direct Connection Initialization CCM/Host Computer Direct Connection without Modems (1) COM, (2) COM AS-232C pon. (3) Computer RS-282C por. (4) Host computer. Make sure the following equipment is available: + Appersonal computer. Refer to the Caterpillar CCM PC For Windows: Getting Started Manual for specitications on the PC. itis the user's responsibilty to adequately understand the operation of the PC: + The proper AS-2320 cables are required for the particular installation. Refer to the"RS-2320 Cable Requirements section’ in this manual + TheCCMPC For Windows software is available from Caterpillar for use with the CCM,6 Communication initialization Installation Section Procedure Perform the following procedure to initialize communication with the host computer connected directly to the CCM, NOTE: In the following steps the PC should be tured OFF before connecting or disconnecting cables to the serial ports, 1. The CCM should be installed with all wiring attached. Refer to sections on “Wiring Connections and Battery Power" and “General Wire and Cable Snectfications’ section. 2. Determine the communication parameters to be used in the installation, The factory defautt paramaters stored in the CCM are 9600 serial port communication rate (bits per second or bps}, no parity, 8 data bits, and 1 stop bit. These parameters will work well in most installations. Refer to ‘Determining Programmed Communication Parameters in CCM" section in this manual for help in determining the communication parameters stored in the CCM. 3. Load the CCM PC For Windows software into the PC, Refer to Caterpillar CCM PC For Windows: Getting Started Manual tor additional instructions, 4, Goto the Data Link pull-down menu, select Select ECM, CCM. Select the Utilities pull-down menu and select CCM Configuration. Set up the communication parameters of the CCM to match those in Step 2. 5. Go to the Phone Book pull-down menu and select Add or Edit. Set up the communication parameters of the PC to match those chosen in Step 2. 6. The electronic controller of each engine must be programmed with the correct engine number to identify them to the CCM, The electronic controller is proaramimed to Engine Number 1 at the factory. Refer to Programming the Engine Number section in this manual to change the engine number programmed inlo the electronic controller. 7. After the CCM and the PC are all properly connected, refer to the CCM PC software Users Manual for instructions on monitoring and Controlling the engine remotely, NOTE: Two conditions must be met before the electronic engine controler wil allow Coritrol (starting and siopping, for exarnple) by the CCM. Tne Engine Control Swiich must be in the AUTO position, and the remote intiate contacts must be ‘open (no other remote start signal received). The ‘engine may be monitored with the ECS in any position. NOTE: For EMCP ! applications, the CCM annot control the genset if the GSC is in i Service Mode, however the genset can still be Monitored. Remote (Modem) Connection initialization CCM/Host Computer Remote Connection with Modems (3) COM. (2) CCM RS-232C pont. (3) Answering modern. (4) Telephone line. (5) Originating moctem, (6) Computer's RS-2326 port. (7) PC computer. (6) Modem RS-232C por. (8) Modem phone line port If desired, follow the instructions in the previous section to connect the CCM directly to the host computer before attempting modem connections. This enables the user to become familiar with the PC software and verity proper operation of the genset while at the site Make sure the following equipment is available: « APC with a terminal emulator software prograrn installed. Examples gf terminal emulators include: ProComm®, PC-VT®, or Terminal under the acessories window in Microsoft Windows™. Refer to the Caterpillar CCM PC For Windows: Getting Started Manual, for further specifications. It is the user's responsibility to adequately understand the operation of the PC. + The proper RS-232C cables. Also, acable must be temporarily connected from the PC to the Answering Modem RS.232C port. Reter to the 'PS-282C Cabie Requirements’ section.‘+ Two modems that support the Hayes AT command set. This is necessary for oth the Answering Modem and the Originating Modem, + The CCM PC For Windows software is available from Caterpillar for use with the com. NOTE: Some PC’s will have a built-in modem, It is possible to use one of these internal modems as the Originating Modem as iong as itis compatidie with the Answering Modem. Consult the instructions for the two modems. Procedure The following steps set up proper communication between the CCM and the Answering Modem. The Originating Modem is sel up later by the PC sofware (refer to the CCM PC software Users Manual) NOTE: In the following steps the PC andthe modems should be turned OFF before connecting or disconnecting cables to the serial ports. 1. The CCM should be installed with all wiring attached. Refer to sections on “Wiring Connections and Battery Power” and “General Wire and Cable Specifications". 2. Determine the communication parameters to be used in the instalation. The factory defaut parameters stored in the CCM are 9600 serial port Communication rate (bits per second or bps), No; Parity, & data bits, and 1 stop bit. These Parameters will work welll in most installations. Refer to*Determning Programmed Communication Parameters in CCM" section in this manual for helo in determining the corrmunication parameters stored in the CCM. 7 Communication initialization Installation Section NOTE: RS-2320 serial port communication rate is often referred to as DTE speed or bits per second (ps). The phone port communication rate of the modems is often referred to as DCE speed or bps. 3. Using the proper cable, connect the AS-232C port of the Answering Modem directly to the RS-282C port of the PC. This connection is temporary and must be done to set up the Answering Modem. 4. Using the terminal emulator on the PC, set the serial RS-232C port for the communication Parameters determined ini Step 2. 5. Several commands must be sent to the Answering Modem that set tne communication Parameters to the proper values. The examples given are Hayes AT commands and are for ilustration purposes only. Actual command sets, Vary widely between modem manufacturers. Consult the manual for the modem. If desired enter the proper command for the particular Modem in the biank "User's Modem Commang* column of the chart on the following page. NOTE: In the following AT commands the symbol *0" indicates the number zero.18 Communication initialization Installation Section [THEA ANSWERING WODEN SETUP COUTANDS 1 may eee «@ Cn eaten ae | as Mora. Tin bn Ser epee connars ent teat conmene | for error contol. Set to communicate n asynenroncuss mage wih a separate ommend (S80 6.) * ‘Set9 communicate in asynchronous mace. aTaQD NOTE: ithe 85 commands supported, ine modem is aeacy lasynonrongus mode, and ine commanc! ould ct be Sent ‘Sel Aulo Anower ON, This ells the madam to answer the phone line afi the ATSoet : fisting. let al, ine modem wilinever anewer an incoming cal, The value ot ths register can be seen with te ATSO? commans. @ | Set Flow Control io XONMOF? This ue off ATSICTS hardware nencsnaking Area ween the modem and CGM, since the CCM Goes not have RTS o” CTS ines. Irtums on the XONIXOP® software nancsnaiing, 1 | Se1DCD to rack statue of carrier detect signal. This causes the DCD ine trom ATECT ‘ne modem fo folow he stale of ie phone line caer. When thecal to the CeMs modem has been mace and tne macem to modem Randshaking is done, the DCD Ine wil change and alow ibe CCM to receive cate NOTE: This ie very important. "ine DOD me is nota the right state, the CCM cannot receive data @_) S#1 STR to mentor DTA signal ang hang ub ana reeat modern aio a} ‘ Bis iranston. ni cevsesthermademfo hang ub and eset # he CCN srope : the orm ine | Resut cooee ao not haveto be retuned, Or thay ae etured hey mus be AIG imonighate mece, bustin answer "rece CJ [tore rnaton reson diy ase ove isan Oeeconae Tae | _ATER5=#0 feng woul eause re mace f9 Feng uD the ine 2 © eacend ster te OTR line from te COM changes | NOTE: eter your Barteuiar manual. Some modems spect he time in “0th ofa eeond and some in 1/10n ota secon t ‘Set delay belore forced hang-up to maximum value ise than 8 eeconds. KISS8=2 |_| Wrte tne cetun parameters rio memory0. When ihe satin peramatersarewritln, | ATEWO any het wore hol changes ate ares ni he merry h her orignal sate 7 _| Sette recali memory 0 on reset ‘yevO | m _| View ine mocem active prota. Thi an optional commen that alows the user ATR lo view tye above parameters stored in the modem. Thay should be verte oun en saveuta ture serene | This completes the setup of the Answering 8. Goto the Data Link pull-down menu, sel Modem. Select ECM, CCM. Select the Utilities pull-down menu and select CCM Configuration. Set up the communication 8. Disconnect the PC from the Answering parameters of the COM to maton those chosen Modem. Temporarily connect the PC directly in Step 2 to the Me the "RS-232C Ie 7 Reuaramsnte sean ee 8, Goto the Phone Book pulldown menu and 4} sélect Add or Edit. Set up the communication i 7. Load CCM PC For Windows software into parameters ofthe PC to match those chosen in| the PC. Refer to the Caterpillar COM PC For Step 2 { Windows: Getting Started Manual, for } instruction on monitoring and controlling the j engine remotely (Marine applications a0 nat allow remote control aoilty, only monttring is provided)10. The electronic engine controller of each engine must be programmed with the correct ‘engine number to identify them to the CCM. The electronic engine controller is programmed to Engine Number 7 at tne factory. Refer to Programming the Engine Number section in this manual to change the engine number programmed into the electronic engine controlier. 11. Disconnect the PC from the COM. Connect tne PC, modems, and CCM, as noted in the RS-232C Cable Requirements section of this manual, Make sure that the Answering Modem and the CCM are both powered up and that they are connected by the proper PS-232C cable, 12, Power-down the CCM (remove the wire connected to the B+ terminal of the CCM) and then power-up the CCM (reconnect the wire on the B+ terminal). During this step, make sure that the CCM remains powered up for 2 minimum of 30 seconds. The CCM sends commands at power-up that set the DTE speed of the Answering Modem to the same as that of the CCM. 13. After the CCM, the modems, and the PC_ are ali properly connected, refer to the CCM PC software Users Manual for instructions on monitoring and controlling the engine remotely. NOTE: Two conditions must be met before the electronic engine controller will alow contro\ (Starting and stopping, for example) by the CCM The Engine Control Switch must be in the AUTO position, and the remote initiate contacts must be open. The engine may be monitored with the ECS in any position. NOTE: For EMCP Ii applications, the CCM cannot controi the genset if the GSC is in Service Mode, however the genset can still be monitored. NOTE: If desired, the PC and the Originating Modem can be connected to a local phone line at the same site as the genset, CCM, and Answering Modem, to make certain of proper communication before attempting remote operation 19 Communication Initialization Installation Section20 Troubleshooting Maintenance Section Troubleshooting € \ CCM Error Code Troubleshooting ‘The CCM has internal troubleshooting to aid the operator in soiving various system problems such as CAT Data Link or RS-232C communication ‘errors and/or CCM battery failure. Other types of faults are included in the “Additional Troubleshooting’ section. Also, refer to the Caterpillar CCM PC For Windows: Getting Started Manual, for additional information. NOTE: For the older CCM (Caterpillar part number 117-6170), the logged faults will appear on the CCM display every 60 seconds, each for 2 seconds. This flashing fault log will not appear for any other version of CCM. This log can be cleared using the CCM PC software. ew ERROR COOES oH enti lace otntion clon Rei ee , C Pan Colne miawene ammninemarcaaes | Gt ® | Sanpete tats Sine noone veo) CREE Tan Cees teomes Revomnate Bae Teese re Chet coer gerraea EX coee tina fe cout oro 255 ray bse bate yest Sarge be ts Feng COMBS Scio Soe) ASAE or ret aak | Oreck 46-2900 cable PC eo andCOW Be 205] erent cern STREET | Fore cause by «sows an acca covmantaing one ei PER ose Samia eae ee re eae oe es EAT Seer I pais GA baa ik herape at] cutesy YSSalnwatioon CA Dati 69 Caerleon coven 0) 2 aaa | ve ECAP or one Ca an im ches ST Duele asso nat Cay Fike owe un nome (ate £ anette ntsc Ceres ms Cink naan 15-220 wopou cowraneamn vam Guat sono bay he raat aa ease rena cota ese e K @:€)9 Additional System Troubleshooting The purpose of this section is to aid the operator in solving those problems that are NOT accompanied by an error code on the CM and are NOT included in the Caterpillar CM PC For Windows: Getting Started Manual 21 Troubleshooting Maintenance Section "ADDITIONAL SYSTEM TROUBLESHOOTING Problem Possible Explanation Tetion Required Direet Connections PC unable to connect to GoM PC configured mpropery or @ cabing ‘wroris present Determine # he proper serial port on ine PChae been selected. Maka eure the correct RS-2320 cables being used. Nul adem is required. Match ne PC wi the CoM connguraion Modem Connections PC unable to connect to COM PC contigured improper, mocem nol set Up propery, or cabling sori present Pomogem anc COM mocem ae not compatibie. Pessword was not entered within 60 seconde Daterrine f proper serial pot on the PCE selectec, Make sure that the ‘Communicanan Speciiesions are beng Sure the correct RS-232C cable = Deng Used. Norull macem Ierequred. Match the CON, PC, and macem eonigurations ‘Modem disconnects curing remote start ‘System battery volageis low Wake sure that he (/-) Batory Power Speciications are beng met. t may be necessary to cisconnee! the phone line on te local modem temporal fo force 10 hang wo. FC can connect to only ene electronic controller n'a multinie Uni nsiaiaion, ‘cvonie controler WiD Ras not baen programmed Electronic contolies ate not connected on he correct data ink Feler tothe Programming the Engne Number section and CCMMData Line Gudeines eectionm this manda PC wil not connect to 95008 manne propulsion engine when using the CC? Eotoware ‘CCM nas been installed on the wrong Gata tee. ‘COM PC sofware verson 1.2 and earler ‘llnot communicate with the COM I he CcMie connocted va te primary Data Unk en 25008 Marne Engines Ouit ater 487, The CCM should be connected on the Secondary CAT Date Link on hese. fengines when used as a communications Inletace. Reter tothe CGN Data Link Guidetinas section this manual2 Troubleshooting Maintenance Section oN ‘The purpose of this section M5X Communication Troubleshooting is to aid the operator in solving some common problems associated with M5X communication protocol. SX COMMUNICATION TROUBLESHOOTING Problem Direct Connections Possible Explanation ‘ation Required (COM shows error codes £02 and when recelvng data irom the PO/PLC ane willnot communicate “There isa protocol err. The dala isnot ASCI format |_At incorrect checksum was set Correct the massage beng sent to te COM S-282 ogee lights are net fang the CCM wil pot communicate ‘wth te POIPLE even nougr no rer Codes are appeating ‘Cannot jag tothe COM (Cannot get dala rom the GoM Cannot get data rom the electronic canvolier Haraware connection between ine | PospLcTene com i coruptes or Sisconnected Connection probiem exsts or using the wrong MBX protocol or logging ‘The logged it" securty level isnot Righ enough to suppor tne request The COM does not supped ihe FID ‘The siesronic Gonwoler speciied isnot avaiable ‘The oayed in’ securty level isnot high fencugh lo suppor he requedt ‘The electronic controller does not Using the CCM PC software, connected 1 he CC, delermine I the cannecten to the PCIPLC Is vali 6 a read request (PID SFO $12) to vel that he FC/PLC fs avaliable to communicele wh ne CCM. t Valid response is reurned, proceed to "og in" as Gestribed h ihe Logging in section n tis manual. the password has been forgotten. call ne COM Hele Desk. ‘Verily that Pie opged er security Ivel is high enough {support the request Veriy that ne COM euppons the PID beng requested that he elecyonie controller ang the COM are ‘connestedon the same data ink Verity nat he loaned in’ secuty lev! is high enough te suppor the request. ‘Voy that he slectronle controler supports the PID eng reauested ‘Mubipie eaponees are being enorated ftom 2 snge electronic Contober Program the engine number ofthe eacyanic ‘onli. Refer tothe CCM/Dala Link Guicelines section and Programming tne Engine Number section In this manual “an entre broaaeast Ist nol returned 7 broadcast istic retuned, Buti “The electronic controller spesied s not The electione controller does net support any one othe PID's. ‘The PID contains greater than two bytes of data | More than 48 parameters are boing requested from one electronic eontller ‘Move than 48 parameters are beng Fequested irom ane electronic convoler ‘An unused Pib ($00 $00) nas Deen ‘entered in the migale one broagcest ist erty the numero! parameters recuesied rom ihe sectronse sontrole Is equal lo or ees than 48, Reet to the CCN Customizeg System section. ID 10 in tis. ‘erty thatthe total number of parameters requested ftom the electronic controler is equal 0 or lees than 48, Put all unused PID's (806 $00) at he endot a broadcast st Refer to ne COM Customized System section, 10 18 inthis mana '& broadcast lst update rate 6100 stow er meonsisient Cc “Too many patameiers ave beng requested AI-2S2 cable s sion ‘arly that to RS-262 and madam baud rales are at Yeast 9600 baus CCW cannot broadcast mare man 40 parameters per second. Use IID 13, Eye? to siow the upcate rate fo: stable Darametere such as nour meter ternperalue, diagnosis, et, Use & laste rate fr are dynamic paramatire such as engine epees, ol pressure, ele Reler tothe Ro-252 Communication rotoco fot Customizea Systems section In hve manual fo turther Intermaton23 Determining Programmed Communication Parameters in CCM Determining Programmed Communication Parameters in CCM The cornmunication parameters (communication rate, parity, number of data bits, and number of stop bits) are stored in non-volatile memory within the CCM, To read these communication parameters, follow these steps: 1. Power down the CCM (remove the wire connected to the (+) 5 terminal) 2. Power-up the CCM [reconnect the wire to the (+) B terminal]. During the power-up sequence, the CCM display undergoes a lamp test (8.8.8.), followed by the communication protocol parameters (n8i 9600 E00) that have been programmed into it BBS. Abi 9600 EO 8.68_| Alleegments tuned on for wo second lao ict | No party (cetaut valve) 8 | Eight cata Dis (ceteut value) 1__| One stop bit (taut value) 3600_| Communication rate (detaut valve) 00 Errorcode ndicaiing no faults are resent ‘These parameters can be programmed to different values. For the reprogramming procedures, refer to the Phone Book Tool section in the Caterpillar CCM PC For Windows: Getting Started Manual. Maintenance Section Replacing the CCM Battery The CCM contains a battery (Caterpilar part number 107-1785) that supplies power for internal memory whenaver the CCM is powered-cown. in single Unit installations, the CCM! power is OFF whenever the genset control power is OFF. The battery has an expected ife o! five years. ‘The battery is mounted to the inside of the front plate of the CCM behind the three-digit display. To replace the battery, follow these steps: 1. Remove the tour screws seouring the front plate to the housing, 2. The battery is held in place by two smal ‘tabs on the upper and lower side of the battery A tie-wrap provides additional support a. Remove the tie-wrap. b. With a small screwdriver carefully pry one tab and it that side of the battery slightly ¢. Repeat for the other tabs and remove the battery. 3. Carefully press the replacernent battery into the holder until tabs are securing the battery a. The battery has one comer thatis angled to make Sure proper polarity is maintained during installation b. Make sure the battery pins are entering the sockets of the holder properly. ¢. Install the new tie-wrap. 4. Replace the front plate of the CCM24 RS-2320 Communication Prot. CCM Customized Systems Section RS-232C Communication Protocol for Customized Systems As purchased, the Customer Communication Module (CCIM) comes with Windows compatible software that utilizes M5X protocol to allow the CCM to communicate with a remote personal computer (PC). In some installations, the user will require customized software when a host device other than a personal computer [such as a Programmable Logic Controller (PLC) is used or when the application requires enhancements tothe PC software provided. The CCM communicates with the host computer via a standard RS-232C serial data link. This serial data link uses M5X protocol to send and receive data. The MSX commands aliow the user to periodically request a broadcast of mullipie engine or generator parameters for monitoring by the host device Single parameter read and write commands allow the user to control the engine from the host device. The Remote PC software creates up to eight lists that are stored in non-volatile memory in the CCM. These lists contain multiple engine or generator parameters thal are broadcast to the host device from the CCM through the RS-232C network. The engine parameters are given a unique parameter identifier (PID), refer to Parameter Identifiers (PID) section for the appropriate application. The CCM provides the communication link between the host device and the engine governed by the electronic controller. Most Caterpillar electronic systems using the CCN will provide 40 to 50 parameters every second to a remote computer system through the RS-232C connection, but other limits may be encountered. When connecting through a modem operating at less than 4800 baud, the ‘throughput will be reduced. For example, using a cellular phone connection operating at 2400 baud reduces the throughput to 29 Parameters per second. | for Customized Systems CAT Data Link loading can also cause reduced system throughput. in some complex systems, such as the marine propulsion appiication, other modules on the CAT Data Link utilize system resources and may reduce the system throughput to 40 parameters per second To optimize deta transfer and minimize communication loading, stable parameters like hour meters, temperatures, and diagnostics should be requested less frequently. Parameters that are nore dynamic such as engine speed and oil pressure can be Tequested more frequently. Use good design juagment to determine the update rate of individual parameters. ‘The MSX command messages sent to the CCM must always be sent in ASCII format, and the MBX status replies will always be retuned in ASCII format. The command message contains an Instruction Identiier (IID). Numbers preceded by $ are in hexadecimal form. i : a 4 Standard Preamble The first four bytes of every IID contain a standard preamble. The standard preamble is 50 xx yy zz. The 50 indicates MX protocol, The xx is the sending module identifier (CCM or PC). $00 = User's host device $01 = Customer Communication Module The yy is the Instruction Identifier (11D) ‘$00 = Special Parameter Command Broadcast Response Activate A Broadcast List Deactivate A Broadcast List Create 4 Broadcast List Status Reply To NID 11, 12, 13 Single Parameter Read Request Single Parameter Read Response Single Parameter Write Request i Single Parameter Write Response The 22 is the number of bytes in the message after this byte. It does not include the checksum or carriage return: i ID 00, IID 24, and IID 34 all read or write data values of certain PID's,RS-232C Communication Protocol for Customized Systems M5X Message Checksums The second to last byte of every IID is the checksum, folowed by an ASCII carriage return (800). The checksum is the 2's complement of the sum of the preceding bytes of the message truncated to the least significant byte. The sum of the checksum and the preceding bytes will equal in the least significant byte. Example: The following message is sent 5000240400580082AE The checksum for this message is AE. Although the message is sent in ASCIi, the checksum must be calculated using the hexadecimal values. ASCII Hexadecimal Byte Valve aiue 50 $25 $90 $50 0 $00 $30 $00 2a 82 934 24 04 00 $34 $08 oo $30 520 00 58 ss5t36 $88 oo 800 $30 $00 82 858 992 seo Total 152 Truncated to LSB $52 2's Complement (Checksum) SAE Total $100 ‘Truncated to LSB 800 PID Security Levels Every PiD has an associated security level (0, 1 2, or 3) within the CCM. A user within a paricular security level may use PID's in that level or lower levels. PID's cannot be accessed by the user in levels higher than the password allows. For ‘example, a user with security 2 level can access level 2, 1, and 0 but, not level 3. The answering modem will be hung up if the password is not entered (sets the security level) within one minute. Specifically, if DCD is held low by the PC, and the security level is at for more than one minute, DTR will Be toggled by the CCM (answering modem hung up). Also, if the RS-232C cable is disconnected for more than five seconds, OTR will be toggled, and the security ievel will be set to 0. 25 CCM Customized Systems Section The following chart defines the PID’s within each security level for CCM parameters. PID SECURITY LEVELS Teaver io PID (0 | $00 $80 (f}, SAA S8A (W).8RO $12 (AM SFB S14(F) | $00 800 (A) $00 862 (R). SFO.$12,(W)", SFE $01 (A) $00 $00 (Wi), $F S72 (W) ‘SAA 572 (RW), SAA SB? (RW), S4A SEB (RW) ‘SAA $00 (RW), SFO S12 (H)', SFE 80% (), SF8S14(W) user can wite is parameter only ‘aleve equal to than the logged in secunty level. NOTE Re Read. W= Wie, Logging In to the CCM Before any parameters can be read or written to the CCMielectronic engine controller, the appropriate security level must be established. This process is called Logging In. The factory Gefault password for all security levels is blank for all security levels, Thus, if no passwords are assigned (use !ID 34 with PID $AA87, PID SAABB, or PID SAAB to set these passwords) there will be an established security level of 3, To ‘log in* using the factory default blank password, use IID 34 for PID SAA SBA: 50003404006 1AA8AE3 ID 38. Single Paramoter Write Request 7 T 5 Byte(s) cons | __Detalted Description ‘$5 ndicales MBX protocol {2 | $00 | Usere PCs ne sencing meaue Fe Ts Tox 4 | $04 | Number of bytes '$00_| Reply in ASCI formal 6 [ser | wpe co 7.8 | SAASBA| PID SAA S8A Logis Pasewor } 2 Cheekeur