Automated data collection from generators

Generator data collection architecture: OrionMeter LA-IP-RSP modules connect to the generators over RS-485 Modbus and send the data over LoRaWAN to the network server and OPCSync, which passes it to an industrial SCADA system over OPC.

Purpose of the solution

This reference solution provides remote monitoring of generator status and operating parameters, including:

phase voltage and frequency;
current, power and power factor;
engine and oil temperature;
oil pressure, fuel level and battery condition;
number of starts, running hours and downtime;
errors, alarms and diagnostic codes.

The device controller reads data from the generator control unit over Modbus RTU via the RS-485 interface. This architecture makes it possible to use the existing industrial controllers installed on most modern generators (for example, Deep Sea, SmartGen, ComAp, Lovato, Kutai and others) without modifying the equipment.

Atlas Copco generator in a sound-attenuated enclosure with a controller window in the door, installed on an open site next to a building.

Solution components

Generator controller: controls start, stop and operating parameters of the generator and transmits data over Modbus RTU.
Sensors: measure voltage, frequency, temperature, oil pressure, fuel level, current and other parameters.
OrionMeter LA-IP-RSP communication module: connects over RS-485, reads data from the controller and transmits it over LoRaWAN.
LoRaWAN data transmission medium: reliable wireless communication with low power consumption and wide coverage.
OPCSync service: receives data over MQTT, converts the payload into JSON and produces ready-to-use parameters for SCADA.
OPC UA upper-level interface: integration with SCADA, BMS and other industrial platforms.
SCADA / visualization platform: real-time display of generator operating parameters, alarms and analytics.

Deep Sea Electronics controller behind the window in the generator door: the screen shows “Generator at Rest”, with the start and stop buttons below.

Data exchange architecture

The data exchange architecture is built on end-to-end transfer of generator parameters from the source to the visualization system. The generator controller reads the main operating parameters (voltage, frequency, temperature, pressure, fuel level and others) and transmits them over the RS-485 interface using Modbus RTU. The OrionMeter LA-IP-RSP communication module polls the controller, collects the data, stores it locally and transmits it over the LoRaWAN wireless link. Over the LoRaWAN network the data reaches a gateway, which forwards it over MQTT to the OPCSync cloud service. The service automatically decodes LoRaWAN packets, converts them into structured JSON, creates OPC UA tags and delivers the processed data to enterprise systems such as SCADA, BMS or ERP. At the top level, the data is visualized in real time: current generator operating parameters, alarms, event history and analytics.

Benefits

Remote generator monitoring with no on-site personnel.
Compatibility with most controllers over Modbus RTU.
Reliable data transmission over LoRaWAN in any terrain.
Off-grid operation on solar or battery power.
Integration with SCADA, BMS and other industrial systems.
Lower costs and more reliable power supply.

What makes the solution unique: OPCSync

OPCSync is a proprietary software service developed to integrate LoRaWAN devices with SCADA.

Download Generator data collection: solution overview (in Russian) Files marked (in Russian) are available in Russian only. PDF ← All solutions