Intesis Modbus Server OCPP Gateway

Important User Information

Disclaimer

The information in this document is for informational purposes only. HMS Industrial Networks disclaims any responsibility or liability for any errors that may appear in this document.

HMS Industrial Networks reserves the right to modify its products in line with its policy of continuous product development. The information in this document is subject to change without notice.

The data, examples, and illustrations in this document are for illustrative purposes only and are intended to help improve understanding of the product's functionality and handling. HMS Industrial Networks cannot assume responsibility or liability for actual use based on this data, nor for any damages incurred during installation. Users must acquire sufficient knowledge to ensure the product is used correctly in their specific application and meets all performance and safety requirements.

Gateway Overview

The Intesis Modbus - OCPP gateway facilitates the integration of OCPP devices (EV Chargers) into Modbus TCP and RTU enabled systems or into an external OCPP Central System (CS). It assumes the user is familiar with Modbus and OCPP technologies.

When operating as an OCPP Central System, the gateway manages OCPP signals and operations via a Modbus controller. Alternatively, it can connect to an External OCPP Central System, providing transparent OCPP communication between EV chargers and the external CS, while extracting valuable information for Modbus supervisory applications.

The gateway functions as a Modbus TCP Server or Modbus RTU slave, allowing Modbus client/master devices to read/write its internal points. From an OCPP perspective, it parses data from OCPP messages to Modbus registers or transmits directly to an External OCPP system. Each OCPP installation requires one Central System.

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1 Description

1.1 Introduction

This document details the integration of OCPP devices (EV Chargers) into Modbus TCP and RTU systems, or external OCPP Central Systems, using the Intesis Modbus - OCPP gateway. Familiarity with Modbus and OCPP is assumed.

The gateway can act as an OCPP Central System, enabling a Modbus controller to manage OCPP signals. Alternatively, it can connect to an External OCPP Central System, facilitating transparent communication between EV chargers and the external system while providing data for Modbus supervisory applications.

As a Modbus interface, the gateway operates as a Modbus TCP Server or Modbus RTU slave, allowing Modbus clients/masters to access its internal points. It parses OCPP messages into Modbus registers or transmits them directly to an external system. An OCPP installation requires a single Central System, which can be implemented within a Modbus control system or be an external OCPP Central System.

Use Case Descriptions

Use Case 1: Integration of OCPP EV Charging points into a Modbus BMS (TCP or RTU). This scenario depicts multiple OCPP chargers connected to a HUB, which communicates with the Intesis gateway. The gateway then interfaces via Modbus TCP or RTU with a Building Management System (BMS) or SCADA system, comprising controllers and a Human-Machine Interface (HMI).

Use Case 2: Modbus gateway acting as a bridge between an external OCPP Central System and OCPP chargers. In this setup, multiple OCPP chargers connect to a HUB, which communicates with the Intesis gateway. The gateway then acts as a bridge, connecting via Modbus TCP or RTU to an external OCPP Central System, which is subsequently linked to a BMS/SCADA system.

1.2 Functionality

The Intesis MAPS software serves as the configuration tool for this gateway. For detailed integration steps into a Modbus BMS, consult the Intesis Configuration Guide available at www.intesis.com.

From the OCPP perspective, after startup, EV Chargers attempt to connect to the Intesis gateway, which must be configured as a Central System. The gateway accepts connections only from configured EV Chargers and receives events or updates from them.

When acting as a Central System, the gateway exposes its points as Modbus Registers, readable or writable by a Modbus client/master. Modbus values are translated into OCPP messages sent to the EV Charger.

When connected to an External Central System, the gateway is configured with the external system's IP address to enable transparent OCPP communication between chargers and the central system. It also presents its points as Modbus Registers for Modbus client/master devices.

1.3 Gateway's Capacity

The Intesis gateway's capacity is detailed below:

2 Modbus Interface

2.1 Description

The Intesis gateway acts as a server on its Modbus TCP or RTU interface, connecting via the Ethernet port or the RS485 port, respectively. Modbus client/master devices can access the gateway's points and resources as detailed in this document.

2.2 Functions Supported

The following Modbus functions are supported:

• Functions 01 and 02: Read Modbus registers (coils and digital input registers).
• Functions 03 and 04: Read Modbus registers (read holding registers and read input registers).
• Functions 05 and 15: Write Modbus registers (Single digital Holding Registers and Write Multiple Holding Registers).
• Functions 06 and 16: Write Modbus registers (Single Multiple Holding Registers and Write Multiple Holding Registers).

When reading or writing multiple registers using poll records, all requested addresses must be valid; otherwise, a Modbus error code will be returned.

All registers are 2 bytes, with content expressed in MSB..LSB, regardless of the signal type (bit or other) in the external system.

Modbus error codes are fully supported and sent for invalid Modbus actions or addresses.

2.3 Modbus TCP

The TCP port can be configured (default is 502). The IP address, subnet mask, and default router address for the Intesis gateway can also be configured.

2.4 Modbus RTU

Connect the communication cable from the Modbus network to the port marked 'Modbus' on the Intesis gateway. Connect the EIA485 bus to connectors A3 (B+), A2 (A-), and A1 (SGND), respecting polarity.

The EIA485 bus supports a maximum distance of 1200 meters and a maximum of 32 devices. Termination resistors of 120 Ω are required at each end of the bus.

2.5 Address Map

The Modbus address map is predefined and not configurable. Refer to the Configuration Guide for a list of available registers.

2.6 Points Definition

Each point in the gateway is defined with Modbus Format, Point, and R/W features. The Modbus features associated with each point are:

Bit coding into 16-bit registers is used for some devices to encode digital values, accessible via Modbus function codes 3 and 4.

3 Connections

Information regarding the Intesis gateway's connections:

Power Supply

Use NEC Class 2 or Limited Power Source (LPS) and SELV rated power supply. Respect polarity on terminals (+) and (-). Ensure the voltage is within the admitted range (check table below). The power supply can be connected to earth only through the negative terminal.

Ethernet / Modbus TCP / OCPP

Connect the IP network cable to the ETH connector using an Ethernet CAT5 cable. For LAN communication, consult the network administrator to ensure traffic is allowed on the used port. Upon initial power-up, DHCP is enabled for 30 seconds. If no IP is provided, the default IP 192.168.100.246 is set.

Port Modbus RTU

Connect the EIA485 bus to connectors A3 (B+), A2 (A-), and A1 (SGND) of the Intesis gateway's Port, respecting polarity. The EIA485 bus supports a maximum distance of 1200 meters and up to 32 devices, requiring termination resistors of 120 Ω at each end.

Ensure proper clearance for cables (see section 6).

Terminal Wiring

3.1 Powering the device

A power supply within the allowed voltage range (check section 5) is required.

WARNING! To prevent earth loops that could damage the gateway or connected equipment, it is strongly recommended to use DC power supplies that are floating or have the negative terminal connected to earth. Never use a DC power supply with the positive terminal connected to earth.

3.2 Connection to Modbus

3.2.1 Modbus TCP

Connect the communication cable from the network HUB or switch to the ETH port of the Intesis gateway using a straight Ethernet UTP/FTP CAT5 cable.

3.2.2 Modbus RTU

Connect the communication cable from the Modbus network to the port marked 'Modbus' on the Intesis gateway. Connect the EIA485 bus to connectors A3 (B+), A2 (A-), and A1 (SGND), respecting polarity. Observe standard EIA485 bus specifications: maximum distance of 1200 meters, maximum of 32 devices, and a 120 Ω termination resistor at each end.

3.3 Connection to the configuration tool

To access configuration and monitoring, connect to the device. One method is via Ethernet, using the gateway's Ethernet port.

4 Set-up Process and Troubleshooting

4.1 Pre-requisites

A functional Modbus TCP client or RTU master device must be connected to the corresponding Modbus port of the Intesis gateway, along with connected OCPP devices.

An External OCPP system is required if the External OCPP Central System functionality is enabled.

Connectors, cables, the PC for the configuration tool, and other auxiliary materials are not supplied by HMS Industrial Networks S.L.U.

Items supplied by HMS Networks:

• Intesis gateway.
• Link to download the configuration tool.
• Product documentation.

4.2 Intesis MAPS. Configuration & Monitoring Tool for Intesis Modbus Series

4.2.1 Introduction

Intesis MAPS is Windows® compatible software designed for monitoring and configuring Intesis Modbus series devices. This document focuses on the Modbus OCPP gateway. Installation procedures and main functions are detailed in the Intesis MAPS User Manual, downloadable from the Intesis product website (https://www.intesis.com/).

Consult the Intesis MAPS User manual and Configuration guide for specific parameter details and configuration instructions.

4.2.2 Connection

To configure Intesis connection parameters, click the 'Connection' button in the menu bar.

Figure 4.1 MAPS connection settings: This screenshot displays the Intesis MAPS interface for establishing a connection. It shows fields for Connection Type, IP Address, Netmask, Gateway Name, Serial Number, Application Name, License, Version, and configuration file details. Options to Connect, Disconnect, and enter a password are also visible.

4.2.3 Configuration Tab

The 'Configuration' tab allows parameter setup, divided into three sections: General (gateway parameters), Modbus Slave (Modbus TCP/RTU interface configuration), and OCPP (OCPP configuration and device parameters).

Figure 4.2 Configuration tab – General Configuration: This screenshot shows the General Configuration section, allowing users to set the Gateway Name, Project Description, IP Address, Netmask, and manage USB Host and Security settings.

Figure 4.3 Configuration tab – Modbus Configuration: This screenshot displays the Modbus Configuration section, where users can select the Modbus type (RTU + TCP), configure Byte Order, Notification on MB Write, TCP port, Keep Alive settings, and RTU parameters like Connection Type, Baudrate, Data Type, and Slave Number.

Figure 4.4 Configuration tab – OCPP Configuration: This screenshot illustrates the OCPP Configuration section. Users can select the OCPP Type (BMS Central System or External Central System), specify the IP and Port for an External Central System, and configure Charger settings like Charger ID, number of connectors, and Heartbeat Interval. Smart Charging operations can also be enabled.

OCPP Configuration Window Settings:

• OCPP Type: Select the mode:
  • BMS Central System: Gateway and BMS act as an OCPP Central System.
  • External Central System: Gateway bridges external OCPP CS and chargers. Configure the external CS IP and Port, and use 'Check connection' for testing.
• OCPP Scan: Initiates a search for OCPP Chargers on the network, listing chargers attempting to connect. Chargers must be pre-configured to connect to the gateway for discovery. Refer to the Intesis Configuration Guide for more details.

Figure 4.5 Scan OCPP network functionality: This screenshot shows the OCPP Scan interface, including Scan Status, Start Scan button, and Scan Results listing detected chargers with their IP and Protocol Version. Options to Replace Chargers, Add Chargers, Apply, and Cancel are present.

• Chargers Configuration: Lists available chargers with their ID and connector count. Activating a charger updates the Signals tab. Capacities vary by gateway model.
• Heartbeat interval: Sets the heartbeat timing for OCPP messages.
• TCP Configuration port: Defines the TCP port for OCPP communication with chargers.
• TCP Keep Alive: Sets the inactivity time before sending a Keep Alive message (0 disables it).
• Enable Smart Charging Operations: Activates registers for setting charging profiles, available only for BMS Central System OCPP Type.

4.2.4 Signals

The Signals tab lists all available OCPP signals, their corresponding Modbus registers, and main parameters. More configuration details are available in the Intesis MAPS user manual.

Figure 4.6 Intesis MAPS Signals tab: This screenshot shows the Signals tab interface, displaying a table of signals with columns for Active status, Description, Data Length, Format, Modbus Slave Address, Bit, Read/Write mode, String details, and OCPP Charger/Connector information.

Note: Signal lists and properties vary based on the selected OCPP mode in Configuration.

4.2.5 Sending the configuration to Intesis

Follow these steps to finalize and apply the configuration:

1. Click 'Save' to store the project on your hard disk (refer to Intesis MAPS User Manual for details).
2. You will be prompted to generate the configuration file for the gateway. Select 'Yes' to generate and save the file, or 'No' if the binary file has already been generated.
3. Press the 'Send File' button to transmit the configuration file to the Intesis device. Transmission progress is monitored in the Intesis Communication Console. The gateway will reboot automatically upon loading the new configuration.

Figure 4.7 Intesis MAPS Receive/Send tab: This screenshot illustrates the Receive/Send tab, showing the 'Send' button to transmit the current configuration project to the gateway. It includes a note to ensure the Configuration Tool and Gateway are connected.

IMPORTANT: After any configuration change, send the configuration file to the Intesis device using the 'Send File' button.

4.2.6 Diagnostic

The Configuration Tool provides diagnostic tools and viewers to assist with commissioning and troubleshooting. A connection to the Gateway is required to use these tools.

Tools

The Tools section allows checking hardware status, logging communications to compressed files for support, changing diagnostic panel views, and sending commands to the gateway.

Viewers

Viewers are available for checking the status of Internal and External protocols signals. A generic Console viewer provides general communication information and gateway status. A Signals Viewer allows simulating BMS behavior or checking current system values.

Figure 4.8 Diagnostic: This screenshot shows the Intesis MAPS Diagnostic section, featuring a ToolBox with Console, Modbus Slave Viewer, and Signals Viewer. It displays communication status, signal details, and data points.

Note: Signal lists and displayed properties depend on the selected OCPP mode. Refer to the Configuration Tool manual for more information.

4.3 Set-up Procedure

1. Install Intesis MAPS on your laptop using the provided setup program and follow the installation wizard instructions.
2. Install the Intesis gateway at the desired location, such as on a DIN rail or a stable surface. Mounting within a grounded metallic industrial cabinet on a DIN rail is recommended.
3. For Modbus RTU, connect the communication cable from the EIA485 port to the 'Port A' of the Intesis gateway (see section 3).
4. Connect the communication cable from Modbus TCP and/or OCPP installations to the 'ETH' port of the Intesis gateway (see section 3).
5. Power up the Intesis gateway. The supply voltage can be 9 to 24 Vdc. Ensure correct polarity.
6. WARNING! To prevent earth loops that could damage the gateway or connected equipment, use DC power supplies that are floating or have the negative terminal connected to earth. Never use a DC power supply with the positive terminal connected to earth.
7. If connecting via IP, use an Ethernet cable from your laptop PC to the 'ETH' port of the Intesis gateway (see section 3).
8. Open Intesis MAPS and create a new project, copying the template named INMBSOCPxxx0100.
9. Modify the configuration as needed (refer to the Configuration Guide for details), save it, and download the configuration file to the Intesis gateway as per the Intesis MAPS user manual.
10. Visit the 'Diagnostic' section to verify communication activity (TX/RX frames). Successful communication indicates that the Modbus TCP Client/OCPP devices are operational. If no activity is observed, check device operability, baud rate, communication cables, and other communication parameters.

5 Electrical & Mechanical Features

The Intesis gateway features:

6 Dimensions

The gateway has the following dimensions:

• Width (w): 53 mm
• Height (h): 58 mm
• Depth (d): 93 mm

The recommended available space for installation into a cabinet (wall or DIN rail mounting), including space for external connections, is:

• Width (w): 60 mm
• Height (h): 70 mm
• Depth (d): 100 mm