Installing a Gateway in a Generator and Configuring Settings

Use this guide to install a Calculus gateway in a generator, connect it to the generator controller, configure the communication settings, and prove that the data is correct from the controller display through to the dashboard.

The guide follows the order in which the work is actually carried out:

Result

After completing this procedure, the gateway is mounted safely, has an active tunnel connection to the Calculus platform, communicates with the generator controller, and shows values that have been validated against the generator itself.

Phase 1 — Prepare

Complete as much of this phase as possible before travelling to site. Verify details that can only be established on site—such as the available supply, the protected connection point, and the existing controller settings—before changing or wiring anything.

Safety requirements

Warning

Work inside a generator control cabinet must be carried out by a qualified person and according to the generator manufacturer's safety instructions. De-energise the complete generator control cabinet and verify the absence of voltage before installation work begins. Only run or load the generator when the site and equipment are safe to operate.

Access and permissions

Confirm that you have all of the following before you go on site:

• Access to the Calculus platform, with permission to open the gateway and view its General, Settings and Metadata tabs.

• Asset Management and Current Activity permissions. Without these you cannot validate the data in Phase 4.

• The contact details of an authorised portal administrator, in case the assigned gateway type turns out to be wrong.

• A qualified operator arranged for the start/stop test in step 10.

Tools and materials

• The manufacturer's approved programming tool or menu access for the controller (for example the DSE or DEIF configuration software), including any required cable or dongle.

• Laptop with platform access, and a means of connecting to the site network if required.

• Multimeter for verifying supply voltage, polarity and continuity.

• Gateway, DIN-rail mounting parts, antenna, cables, connectors, fuses, glands, strain relief, labels.

• Where required by the bus topology: a 120 ohm termination resistor.

A. Identify the hardware and the assigned configuration

Important

Do not start by changing controller settings. First identify the hardware and determine which values the assigned gateway configuration expects.

Record the following:

• Calculus gateway model, for example C04 or C06.

• Controller manufacturer, model and firmware, for example DSE or DEIF. Other approved controllers may also be available.

• Assigned gateway type in the Calculus platform.

• Target asset and data source in the Calculus platform.

• Available supply voltage, GND, and protected connection point, if known. Verify these on site before wiring.

B. Determine the communication route

The assigned gateway type and its Settings determine which route is used. Do not choose a route only because a connector is physically present.

Once you know the route, resolve only the values for that route in section C.

C. Resolve the Settings and Metadata values

Important

The controller settings must match the effective values in the gateway configuration. Values may be written directly in Settings or supplied through variables in the Metadata tab. Never copy a metadata placeholder literally into the controller.

How to resolve a metadata placeholder

1. Open Gateways, search for the serial number, and open the gateway.

2. On the General tab, inspect Settings.

3. If a field contains a number or address, use that concrete value.

4. If it contains a placeholder such as [#meta:baudrate#], note the variable name between meta: and #.

5. Open the Metadata tab and find the variable with that name.

6. Use its String value as the effective communication value.

Stop if

The variable is missing or empty. Have the gateway configuration reviewed before changing anything on the controller.

C04 — find the baud rate and slave ID

Inspect the Modbus object in Settings:

• Modbus.Baudrate is the baud rate.

• Modbus.Slaves[0].SlaveAddress is the slave ID.

If these contain [#meta:baudrate#] or [#meta:slaveId#], resolve the effective values in Metadata.

Example: if Settings shows a baud rate of 9600 and a slave address of 3, configure the controller for baud rate 9600 and slave ID 3. These are example values, not universal defaults.

C06 — locate the communication definition

Open slaveDefinitions and locate the definition named modbus.rtu or modbus.tcp.

Ignore definitions named ethernet that point to 127.0.0.1 on ports 80 or 22. These are not the generator controller connection.

C06 — values for RS485 / Modbus RTU

• The slave address may contain [#meta:slaveId#]. Resolve it through Metadata.

• baudrate may be a concrete value such as 9600, or a placeholder such as [#meta:baudrate#].

• bus may refer to [#meta:expansionBus#]. This is internal configuration and must not be changed by the installer.

• The controller type in the same definition helps confirm that the correct gateway profile is assigned.

C06 — values for Ethernet / Modbus TCP/IP

In the modbus.tcp definition:

• address is the controller IP address. It may refer to Metadata variable address.

• port is the Modbus TCP port, commonly shown as 502 in the assigned profile.

• slaveId is the unit/slave ID expected by that profile.

Under connectivity.networkPortSettings:

• ipv4StaticAddress is the gateway's own Ethernet IP address. It may refer to Metadata variable ipv4StaticAddress.

• ipv4StaticSubnetMask is the subnet mask used by the gateway Ethernet interface.

Metadata variable address_underscore is the controller IP address with underscores instead of dots, for example 192_168_2_10 for 192.168.2.10. Keep it consistent wherever the selected profile uses it.

Do not confuse the two IP addresses

The controller and the gateway need different IP addresses in the same intended subnet. For example, the controller can use 192.168.2.10 while the gateway uses 192.168.2.20. The controller address belongs in the Modbus TCP definition; the gateway address belongs in networkPortSettings.

Preparation checklist

Before travelling, complete everything that can be prepared remotely. Mark any site-dependent item for verification before wiring or changing the controller:

• ☐ Gateway model, controller model and firmware recorded

• ☐ Gateway type confirmed to match the installed controller

• ☐ Communication route determined from the assigned configuration

• ☐ All effective values for that route resolved and written down

• ☐ Target asset and data source identified

• ☐ Platform permissions confirmed, including Asset Management and Current Activity

• ☐ Controller programming tool and all tools and materials packed

• ☐ Qualified operator arranged for the start/stop test

Phase 2 — Install

Carry out steps 1 to 4 with the complete generator control cabinet de-energised and the absence of voltage verified. Power is applied in step 5 only, once all wiring is complete and inspected.

1. Plan the installation

1. Locate the controller, a suitable DIN-rail position, cable routes, supply terminals and antenna exit.

2. Confirm that all required cables, connectors, fuses, glands, labels and mounting parts are available.

3. Record the existing controller communication settings before changing anything.

4. Decide where the gateway and antenna will be mounted without obstructing service access.

2. Mount the gateway and antenna

1. Mount the gateway firmly on a DIN rail in a dry, accessible and mechanically protected location.

2. Keep all connectors accessible for commissioning and future maintenance.

3. Route cables through existing cable ducts where possible and add strain relief.

4. Separate communication wiring from high-current and switching cables as much as practical.

5. Protect every new cable entry with a suitable gland.

6. If the gateway uses an external cellular or GPS antenna, mount it outside the metal enclosure. Avoid sharp cable bends and seal the entry against dust and water.

Checkpoint

The gateway is fixed, connectors remain reachable, the antenna is not shielded by the metal cabinet, and cable routes do not prevent generator maintenance.

3. Wire the power supply

Keep the supply isolated throughout this step.

1. Use the wiring diagram for the installed gateway model.

2. Verify supply voltage, polarity, GND, conductor size and protective fuse.

3. Connect the gateway to the approved generator supply point.

4. Inspect and measure the connection.

Stop if

The expected supply voltage or polarity cannot be confirmed. Do not use a convenient terminal without verifying its function and protection.

4. Wire the generator controller

Follow the route you determined in preparation section B. Wiring only — the communication values are entered in step 6.

Route A: RS485 / Modbus RTU

1. Use a suitable twisted pair for Data+ and Data−.

2. Connect Data+ to Data+ and Data− to Data−. Labels such as A, B, + and − vary by manufacturer; A is not universally Data+.

3. Connect GND only where it is specified for the installation or controller.

4. Avoid star connections and long stubs on the RS485 bus.

5. Check whether termination is required. A 120 ohm resistor is normally placed at the end of a bus, not automatically at every device.

6. Route the cable away from high-current conductors and switching components.

Checkpoint

Polarity is correct, conductors are secure, the cable route is clean, and termination matches the bus topology.

Route B: Ethernet / Modbus TCP/IP

1. Connect the gateway and controller with a suitable Ethernet cable, or to the approved network infrastructure.

2. Confirm that the controller IP address and the gateway IP address you resolved in preparation are different and belong to the intended subnet.

Checkpoint

The cable is routed and secured, and the two devices have unique planned addresses in the same subnet.

5. Energise and check the LEDs

1. Confirm that all wiring from steps 3 and 4 is complete, inspected and secure.

2. Restore the supply and power the gateway.

3. Check the relevant power and status LEDs.

4. For Route B, check the link LEDs on both Ethernet ports.

Stop if

The power or status LEDs do not behave as described for the gateway model. Re-check supply, polarity and fuse before continuing.

Phase 3 — Commission

6. Configure the controller

1. Open the controller communication settings using the manufacturer's approved tool or menu.

2. Enable the required Modbus server/slave function if the controller requires it.

3. Enter the effective values you resolved in preparation section C:

   • Route A: baud rate, data bits, parity, stop bits and slave ID.

   • Route B: controller IP address, subnet mask, Modbus port and unit/slave ID.

4. Save the settings and apply any controller restart required by the manufacturer.

5. Record the final values in the installation notes.

7. Verify the platform configuration

1. Confirm that the gateway type matches the installed gateway model, controller and physical communication route.

2. Use Settings only to read the configured communication values. Do not edit Settings in this procedure.

3. Confirm that every referenced Metadata variable contains the intended effective value.

4. Confirm that the data source is linked to the intended asset.

Controlled actions

Edit Metadata only when the correct approved values are known. A Metadata change can alter live monitoring.

When to restart the gateway

Restart the gateway after any authorised change to Metadata so that the new values are applied. A restart is not a general troubleshooting step.

8. Confirm the tunnel connection

1. Confirm that the Tunnel connection state is active.

2. Confirm that gateway telemetry has a recent timestamp.

Do not continue to Phase 4 until the tunnel connection is active and the gateway configuration matches the physical wiring and the controller settings.

Phase 4 — Validate the data end to end

A connection is not accepted merely because some data appears. Validate the chain in this order:

1. Controller display — the source value on the generator.

2. Asset Current Activity — controller values received through the gateway.

3. Dashboard — values delivered to the intended user-facing asset.

Gateway versus asset

The gateway's Current Activity contains gateway telemetry and communication or parser errors. Controller values such as engine speed, frequency, controller battery voltage and run hours are validated in the asset's Current Activity.

9. Compare static values

Compare the controller display with the asset's Current Activity.

Always check the Last activity timestamp as well as the value. A plausible value with an old timestamp is stale data, not a working connection.

10. Run a controlled dynamic test

1. With the generator stopped, record status and several reference values.

2. Start the generator under the supervision of a qualified operator.

3. Confirm that status, speed, frequency and other relevant values change in the asset's Current Activity.

4. If safe and permitted, apply load and confirm that current and power values react logically.

5. Stop the generator.

6. Confirm that status and dynamic values return to a logical stopped state.

11. Verify the dashboard

1. Open the dashboard for the intended asset.

2. Compare the same values you checked in step 9.

3. Confirm that the timestamps are recent.

Acceptance criteria

The tunnel connection is active; the asset's Current Activity contains recent controller data; no recent parser.error is being produced; at least one status value and several numeric values agree with the controller; start/stop changes are visible; and the dashboard shows the same expected values.

Phase 5 — Hand over

12. Document and close out

1. Store the original and final controller communication settings together with the effective Settings and Metadata values used during commissioning.

2. Complete the final installation checklist.

3. Report any configuration anomaly that was recorded during installation or commissioning.

Reference

Reading Modbus errors

When the gateway reaches the platform but cannot read the controller, a recent parser.error can appear instead of measurements. The exact error content can differ. In this procedure, a current parser.error is treated as an indication that either the physical connection is incorrect or the Modbus settings do not match.

• Check the error timestamp. An old error is historical; a recently updating error is active.

• For RS485, check Data+/Data−, continuity, GND policy and termination, then compare baud rate and slave ID with the effective Settings and Metadata values.

• For TCP/IP, check the link, controller IP, gateway IP, subnet, port and unit/slave ID.

• Use Settings only as a reference. If authorised Metadata values are corrected, restart the gateway and check whether the error stops updating.

Troubleshooting overview

Recipe 1: Tunnel active, but no controller data

1. Check the gateway's Current Activity for a recent parser.error.

2. Confirm that the gateway type matches the installed controller and communication route.

3. Confirm that direct Settings values and referenced Metadata values are complete.

4. For RS485, verify Data+/Data− polarity, continuity, GND policy, termination, baud rate and slave ID.

5. For TCP/IP, verify link LEDs, controller IP, gateway IP, subnet, port and unit/slave ID.

6. Confirm that Modbus communication is enabled on the controller.

7. If Metadata was changed, restart the gateway and check Current Activity again.

Expected result: recent controller values appear and the active error stops updating. If not, preserve the Settings, Metadata values and error details for support.

Recipe 2: Asset Current Activity is correct, but the dashboard is not

1. Stop troubleshooting the controller connection; it is already delivering correct data.

2. Verify that the data source is linked to the intended asset.

3. Check the link's status and applicable time range.

4. Check the dashboard widget configuration, data source and selected time range.

5. Compare one known value between asset Current Activity and the dashboard.

Expected result: the dashboard shows the same recent values already proven on the asset.

Recipe 3: Values are present but stale

1. Check the tunnel connection and the timestamp of gateway telemetry.

2. Check whether a recent parser.error is updating.

3. Check the effective Settings and Metadata values.

4. Check the asset-data-source link and its time range.

5. Restart the gateway only if Metadata was changed.

Expected result: values update again, or the failure is localised to the gateway connection, the Modbus read, or the asset link.

Final installation checklist

• ☐ Gateway mounted securely and serviceable

• ☐ Antenna outside the metal enclosure and cable entry sealed

• ☐ Supply verified, protected and labelled

• ☐ RS485 or Ethernet wiring checked

• ☐ Gateway type matches the model, controller and physical interface

• ☐ Settings read without modification and effective Metadata values resolved and recorded

• ☐ Controller communication settings match the effective gateway values

• ☐ For C06 over TCP: controller and gateway IP addresses are different and in the intended subnet

• ☐ Gateway restarted after any authorised Metadata change

• ☐ Tunnel connection active with recent gateway telemetry

• ☐ No recent parser.error updating

• ☐ Asset Current Activity shows recent controller data

• ☐ Several values compared with the controller display

• ☐ Start/stop test completed safely

• ☐ Asset and data source linked correctly

• ☐ Dashboard values verified

Related documentation

• Installing C06 in a generator

• RS-485 / Modbus RTU connection

• Data not showing: Current Activity

• Data not showing: Data Sources