Exertherm 8 Channel Datacard Configuration & Commissioning Software Guide MA

820102

Exertherm® 8 Channel Modbus Datacard Configuration & Commissioning Tool Guide

MA-117-6-EN

Exertherm® Datacard Configuration & Commissioning Tool Guide

IMPORTANT INFORMATION EXERTHERM MODBUS DATACARD NEW CONFIGURATION TOOL

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Exertherm® Datacard Configuration & Commissioning Tool Guide

IDENTIFYING EXERTHERM DATACARD CONFIGURATION TOOL VERSIONS To find the version of Exertherm Datacard Configuration Tool that is being used, click the ‘Help’ tab and then the ‘About’ tab; the appropriate screen will then be displayed, as illustrated below:

DELETE THIS VERSION

USE THIS VERSION

Version 3.0.6

Fig 1. Delete software versions up to V2.0.14

Fig 2. Only use Software from version V3.0.6

USE OF THE SOFTWARE WITH EXERTHERM DATACARDS IMPORTANT: Configuration Tool version 3.0.6 is backward compatible with ALL Datacards

CONFIGURING SINGLE CALIBRATION SENSORS (IR.06-EM.SC) To configure Datacards using the new version of the Configuration Tool (V3.0.6) with single calibration sensors: • • •

Select the IR.EM-06.SC-Delta T Sensor type from the channel configuration drop down menu The ‘Gain’ factor selection screen will then appear - enter the relevant gain value by cross referencing the busbar size & mounting distance from the IR Sensor Gain Matrix Datasheet DO NOT leave the gain factor at '0' (default setting) as this will result in zero output from sensors

CONFIGURING CALIBRATION A, B, C, D SENSORS To configure Datacards using the new version of the configuration software (V3.0.6) with A, B, C or D calibration sensors: • • •

Select the IR.EM-06.SC-Delta T Sensor type from the channel configuration drop down menu The ‘Gain’ factor selection screen will then appear - enter the value ‘1’ into the gain box for all sensors DO NOT leave the gain factor at '0' (default setting) as this will result in zero output from sensors

If you require further assistance, please contact [email protected]

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Exertherm® Datacard Configuration & Commissioning Tool Guide

1.

VERSION CHANGE CONTROL RECORD Version No

Reason for Change

Created by

Approved by

Date of Release

MA-117-1-EN

Updates

Lisa Kennedy

Dan Thomas

19th March 2015

MA-117-2-EN

Section 6 added + PN

Lisa Kennedy

Dan Thomas

29th Nov 2016

MA-117-3-EN

Version number amend + updated matrix

Lisa JohnKennedy

Ross Kennedy

MA-117-4-EN

Software version amended

Lisa JohnKennedy

John Hope

2019

MA-117-5-EN

Software version amended

Lisa JohnKennedy

John Hope

31st March 2020

11th June 2019

Updated software screenshots MA-117-6-EN

Company name change updates

Lisa JohnKennedy

LJK/JH

11th May 2020

THIS IS A CONTROLLED DOCUMENT: UPON RECIEPT OF A NEW VERSION, PLEASE DESTROY ALL PREVIOUS VERSIONS HELD AND UPDATE ANY RECORDS / PROCEDURES WITH THE CURRENT VERSION

1.1 USING THIS MANUAL This manual contains information that is fundamental both to the operation of the Exertherm system and to operator safety. Please read the manual thoroughly prior to commencing any work. The general hazard (ISO7000-0434) symbol is used where non-observance of the information/instruction might cause hazards to person(s) or the equipment.

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Exertherm® Datacard Configuration & Commissioning Tool Guide Contents 1.

Version Change Control Record................................................................................................................... 4

1.1

Using this Manual ................................................................................................................................................................. 4

2.

Ownership, Notes and Critical Disclaimers .................................................................................................. 7

2.1 2.2 2.3 2.4 2.5 2.6

Notices: ................................................................................................................................................................................. 7 Intellectual Property, Patents, Trade Marks and Registered Designs ................................................................................... 7 Standards and approvals ...................................................................................................................................................... 8 Personnel Qualification and Training ................................................................................................................................... 8 Warranty............................................................................................................................................................................... 8 Live Working ......................................................................................................................................................................... 9

3.

Pre-Commissioning Preparation ................................................................................................................ 10

3.1

Exertherm Datacard Configuration Tool Installation .......................................................................................................... 10

4.

Exertherm Datacard Configuration Tool .................................................................................................... 13

4.1

4.4 4.5

Main Screen ........................................................................................................................................................................ 13 Menu Item Settings: ........................................................................................................................................................... 13 Comms Settings Menu ........................................................................................................................................................ 14 Comms Error message ........................................................................................................................................................ 15 Commissioning the Datacard .............................................................................................................................................. 16 Search Node: ...................................................................................................................................................................... 16 System Parameters: ............................................................................................................................................................ 18 Channel Configuration ........................................................................................................................................................ 19 Gain Factor Adjustment ...................................................................................................................................................... 20 Program Datacard............................................................................................................................................................... 21 Monitor............................................................................................................................................................................... 23 Datacard Configuration Tool Support ................................................................................................................................. 24

5.

Connection to a Front-End Application ..................................................................................................... 25

5.1

Modbus Functions & Registers: .......................................................................................................................................... 25 Node range ......................................................................................................................................................................... 25 Details of Modbus Registers 001…008 ............................................................................................................................... 25 Signed Integer..................................................................................................................................................................... 25

6.

Troubleshooting ........................................................................................................................................ 26

6.1

Datacard Troubleshooting Guide ........................................................................................................................................ 26

7.

Technical Datasheets ................................................................................................................................ 31

7.1 7.2

Data Sheet – IR Sensor Gain Matrix .................................................................................................................................... 31 Exertherm Install & Configuration Record .......................................................................................................................... 32

4.2

4.3

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Table of Figures FIGURE 1 CONFIG TOOL - MAIN SCREEN ......................................................................................................................................................... 13 FIGURE 2 CONFIG TOOL - COMMUNICATION SETTINGS ...................................................................................................................................... 14 FIGURE 3 COMMS ERROR MESSAGE .............................................................................................................................................................. 15 FIGURE 4 CONFIG TOOL - SEARCH FOR A DATACARD ......................................................................................................................................... 17 FIGURE 5 CONFIG TOOL - SETTING SYSTEM PARAMETERS ................................................................................................................................... 18 FIGURE 6 CONFIG TOOL - SELECTING THE SENSOR TYPE ..................................................................................................................................... 19 FIGURE 7 CONFIG TOOL – IR.06-EM.SC-DELTA T GAIN FACTOR ADJUSTMENT..................................................................................................... 20 FIGURE 8 CONFIG TOOL - PROGRAMMING THE DATACARD ................................................................................................................................. 21 FIGURE 9 CONFIG TOOL - MONITOR MODE .................................................................................................................................................... 23 FIGURE 10 DATACARD CONFIG TOOL SUPPORT ................................................................................................................................................ 24

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2.

OWNERSHIP, NOTES AND CRITICAL DISCLAIMERS NO PART OF THIS MANUAL MAY BE COPIED OR REPRODUCED VIA ANY MEANS WITHOUT THE PRIOR WRITTEN CONSENT OF EXERTHERM. THIS MANUAL & IT’S CONTENTS ARE SUBJECT TO CHANGE WITHOUT NOTICE. This document, including all the descriptions within it, assumes that the user is conversant with the operation and uses of basic control and monitoring systems. In addition, this document does not include any specific documentation concerning the systems with which integration takes place. The user should seek additional information from the supplier’s documentation for each of the connected systems. Where devices such as display panels and personal computers are used, we have assumed that the user will either be familiar with the operation of the devices or will be able to familiarise themselves with the information supplied with the equipment. The utility, configuration, terminal or stream modes of the connected systems enable all control parameters to be changed. Competent persons only should carry this out, and it is strongly recommended that any changes made be recorded at the time of the changes. Note that if a change is to be made, a backup of the systems concerned should be made before this where possible.

2.1

NOTICES: The information, products and specifications, configurations, and other technical information regarding the products and data contained in this document are subject to change without notice. All the statements, technical information, and recommendations contained in this document are believed to be accurate and reliable but are presented without warranty of any kind, and users must take full responsibility for the application of any products or data specified in this document. IN NO EVENT SHALL EXERTHERM, OR ITS SUPPLIERS BE LIABLE FOR ANY INDIRECT, SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGES, INCLUDING, WITHOUT LIMITATION, LOST PROFITS OR LOSS OR DAMAGE TO EQUIPMENT OR DATA OF ANY KIND WHATSOEVER ARISING OUT OF THE USE OR INABILITY TO USE THIS DOCUMENT, EVEN IF EXERTHERM HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THIS LIMITATION OF LIABILITY WILL PREVAIL OVER ANY OTHER TERMS & CONDITIONS RELATING TO THE SUPPLY OF EXERTHERM PRODUCTS / SERVICES.

2.2

INTELLECTUAL PROPERTY, PATENTS, TRADE MARKS AND REGISTERED DESIGNS Exertherm is a registered trademark. The infrared (IR), EM Cable Sensors and LoadMap software, are patent protected. The Exertherm suite of products including but not limited to; Exertherm, Exertherm LoadMap, IRt/c.EM & EM Cable Sensor contain proprietary information and intellectual property of Exertherm. Exertherm will vigorously protect itself in the event of any misuse of any or all such intellectual property. All other products or services referred to in this document are the trademarks, service marks, or product names of their respective holders.

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2.3

STANDARDS AND APPROVALS Exertherm IR, EM Cable, Contact / Ambient sensors, and the Exertherm Modbus Datacard are all approved to UL 61010-1 and CAN/CSA C22.2 No. 61010-1. Exertherm IR, EM Cable, Contact / Ambient sensors and the Exertherm Modbus Datacard are all CE approved. Exertherm declare that all our components are produced in accordance with EU Directive 2011/65/EU requirement for RoHS Compliance.

2.4

PERSONNEL QUALIFICATION AND TRAINING All personnel involved in the installation and commissioning of Exertherm must be fully trained and certified by Exertherm. It is assumed those involved in designing Exertherm into electrical infrastructure have received and are conversant with the contents of this document. It is the responsibility of the organisation performing the installation / configuration / commissioning of the Exertherm products to ensure the competency, and supervision of those undertaking such tasks, together with all necessary safety procedures in accordance with international, national, regional, and local regulations and codes. Only persons who have the requisite level of knowledge, skill and appropriate training should install Exertherm products.

2.5

WARRANTY Exertherm IR Sensor, EM Cable Sensor, Contact / Ambient Sensor, Modbus Datacard & ARM XL Return/Warranty Policy Exertherm offers a lifetime warranty on IR Sensors, EM Cable Sensors and Contact / Ambient Sensors from date of sale. We warrant that these products will be free of defects in material and workmanship and will repair or replace the returned product at no charge during that period. The warranties are void if the product is misused, mishandled or installed incorrectly (not in accordance with the methods and procedures specified in this document); keeping the products within specified temperatures. Exertherm offers a 2 year warranty on all other Exertherm product from date of sale. We warrant that these products will be free of defects in material and workmanship and will repair or replace the returned product at no charge during that 2 year period. The warranty is void if the product is misused, mishandled or installed incorrectly. The warranty is conditional upon the above caveats and strictly limited to the replacement cost of the Sensors / Datacard / ARM XL. Labour costs associated with removal of Sensors / Datacards / ARM XL and/or re-installation are excluded, as is any consequential loss resulting from the Sensor / Datacard / ARM XL failure. Exertherm reserves the right to examine and test any returned products to determine the cause of failure. No returned products will be accepted prior to issue of a Return Material Authorization (RMA) number by Exertherm. Please contact Exertherm if you have any questions – [email protected], current telephone numbers can be found at www.Exertherm.com .

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2.6 LIVE WORKING DO NOT PERFORM ANY ACTIVITY ON A PIECE OF LIVE SWITCHGEAR. FAILURE TO COMPLY WITH THESE AND OTHER NATIONAL, REGIONAL OR LOCAL HEALTH AND SAFETY REGULATIONS/GUIDELINES COULD RESULT IN PERMANENT INJURY OR DEATH.

Prior to undertaking any work the operator MUST ensure that all busbars, connections and sources of energy are totally isolated and checked prior to any works taking place this should be completed by a competent trained electrical engineer. All energy sources onto the panel must be isolated, removed and locked out to prevent the panel being re-energised while any works are taking place. If the panel being tested is part of an existing installation then all connections should be bonded to earth potential as an extra precaution and also to stop any possible back feed from other devices.

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Exertherm® Datacard Configuration & Commissioning Tool Guide

3.

PRE-COMMISSIONING PREPARATION The Exertherm Configuration and Commissioning Kit [part no. 800447] includes the Datacard Configuration Tool and a commissioning cable; both of which are needed in order to commission the Exertherm system.

3.1

EXERTHERM DATACARD CONFIGURATION TOOL INSTALLATION The “Exertherm Datacard Configuration Tool” will be delivered on an installation USB. Minimum requirements of the PC/Laptop: Windows XP, Vista, Windows 7.0, Windows 8; Windows 10; 1 GB spare hard drive capacity, 1 GB RAM, 1024x800 Screen resolution and a RS232 Serial communication port or USB port with converter (Com 1 to 10)

❶ Insert USB into Laptop / PC ❷ View your USB drive via Windows Explorer and run the setup program:

❸ Click on “OK” to continue setup:

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Exertherm® Datacard Configuration & Commissioning Tool Guide

❹ Please use the specified location for correct operation of the Config Tool, and click the Setup icon:

❺ Click “Continue”.

❻ If this screen appears, always click “Yes”.

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❼ Click “OK” to finish installation.

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Exertherm® Datacard Configuration & Commissioning Tool Guide

4.

EXERTHERM DATACARD CONFIGURATION TOOL

4.1

MAIN SCREEN To run the Configuration Tool, select the icon on your desktop. After starting up the program this screen will be displayed:

Figure 1 Config Tool - Main Screen

MENU ITEM SETTINGS: With the ‘File’ tab function you can open a configuration which has been previously stored when the “Save Config As” function was used to store a previous Datacard’s settings. Configurations will be saved by default in the DATACARD CONFIG TOOL folder as a *.INI file.

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Exertherm® Datacard Configuration & Commissioning Tool Guide

COMMS SETTINGS MENU The Datacard should be connected with a computer using a standard RS232 to RS485, or USB to RS485 interface. Using the Com Settings menu: 1.

Select the correct com port on your PC

2.

Select the correct Baudrate for the Datacard

3.

Select the correct parity for the Datacard

All parameters must match exactly with the settings in the Datacard in order to communicate successfully. Factory default settings are Datacard address 247, baud rate 9600 (9k6) and No parity. Please note: The Datacard is capable of operating at various baud rates: 4800 (4k8), 9600 (9k6) and 19200 (19k2).

Figure 2 Config Tool - Communication Settings

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COMMS ERROR MESSAGE The following error message as shown in Figure 3 may appear for the following reasons:

Figure 3 Comms Error Message

1. Incorrect communication settings have been used 2. The protocol converter is damaged between the laptop and the Datacard 3. No power to the Datacard 4. The Datacard is damaged, or faulty Click OK and reselect and correct the communication settings.

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Exertherm® Datacard Configuration & Commissioning Tool Guide

4.2 COMMISSIONING THE DATACARD SEARCH NODE: Always check if the settings from the ‘Com settings’ are appropriate for the Datacards. There is a search function to find Datacards connected to the system, addresses range from 1 to 247. 1. If the Datacard address is unknown, first enter a start address of 1 and then a stop address of 247 2. Or, if the Datacard address is known: • for example 20, enter a start address below 20, for example 18 • and enter a stop address of a value greater than 20, for example 22.

•

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Then press ‘Search’ – a progress bar will appear as below

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Exertherm® Datacard Configuration & Commissioning Tool Guide

• •

When the search has successfully finished, the online Datacard address will then show in green as highlighted in Figure 4 The Device Address in the system parameters portion of the screen will be pre-set with the found Datacard address.

Figure 4 Config Tool - Search for a Datacard

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Exertherm® Datacard Configuration & Commissioning Tool Guide

SYSTEM PARAMETERS: The Device Address in the system parameters portion of the screen will be pre-set with the found Datacard address. To view the parameters of the connected Datacard, click the read button. The System parameters section allows you to change the communication settings in the Datacard. After changing any settings: •

Press the “Program” button

•

then “Reset” button

•

and then Press the “Read” button in order to check for proper programming.

The changes will take effect after resetting or re-powering up the Datacard. • • • • •

Device Address With the device address selector you can select either the device to communicate with or the new address to program into the current connected Datacard Baudrate here you can select the required baudrate to program into the Datacard Temp unit Option to change the temperature unit of the presented measurements in °C or °F Parity here you can select the required Parity to program into the Datacard Serial # and Firmware version shows the current serial number and firmware version

Figure 5 Config Tool - Setting System parameters

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Exertherm® Datacard Configuration & Commissioning Tool Guide

4.3

CHANNEL CONFIGURATION From the dropdown, select the correct Sensor type for each channel of the Datacard, this must be carried out to allow the Datacard to display the correct temperature data. The following Sensor types are available: • • • • •

No Selection: Channel Inactive; IR.EM-06.SC-DeltaT: for IR EM-06.SC Sensor IR-01 Absolute: for IR 01 Absolute Sensor Cable EM-DeltaT: for EM Cable Sensor Cable Absolute: for Contact/Ambient Sensor

Figure 6 Config Tool - Selecting the Sensor Type

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Exertherm® Datacard Configuration & Commissioning Tool Guide

GAIN FACTOR ADJUSTMENT The only Sensor that utilises the gain factor is the IR.EM-06.SC-DeltaT Sensor. When selecting the IR.EM-06.SC-DeltaT the gain adjustment window will appear to the right. The initial value here when selecting IR.EM-06.SC-DeltaT is 1.00. You MUST amend the relevant ‘gain factor’. It is imperative that the correct value is entered otherwise values will be inaccurate. This gain factor is taken from the Exertherm Install & Configuration Record for that Datacard, which should be provided by the install team. For your reference a copy is provided in Section 7.1 and 7.2 Gain is not operative until the Datacard is programmed.

Figure 7 Config Tool – IR.06-EM.SC-Delta T Gain Factor Adjustment

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Exertherm® Datacard Configuration & Commissioning Tool Guide

PROGRAM DATACARD Now that all Datacard parameters are complete, they must be programmed into the Datacard. Ensure the Datacard address in the upper left corner of the screen is correct address you wish to program. 1. Then press the “Program” button to program the parameters from the PC into the Datacard. 2. A confirmation message will appear, press OK.

Figure 8 Config Tool - Programming the Datacard

3. Progress bar will move until programming is complete. The TX RX and ACK LEDs will flash while programming.

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Exertherm® Datacard Configuration & Commissioning Tool Guide

4. The Datacard has now been programmed successfully, click OK

5. Then acknowledge the ‘Verify’ message and click OK.

6. Then press the RESET to allow the new parameters to operate. 7. Then press the “Read” button to retrieve the parameters from the connected device to the PC. 8. Progress bar will move until reading is complete. The TX RX and ACK LEDs will flash while reading. 9. The Datacard has now been read successfully, click OK.

10. The screen is now populated with the program settings. 11. Now that valid channel types have been programmed, the green status LED will be lit against the channel name.

If a number of the Datacards are being commissioned on a network then ONLY ONE at a time can be addressed and setup. Therefore, all units further down the line either need their power removing or network cables unplugged. Once each Datacard is commissioned its network cable can be reconnected and new settings can be programmed into the next Datacard with address 247. Page 22 of 32

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Exertherm® Datacard Configuration & Commissioning Tool Guide

4.4

MONITOR With the monitor function you can test the configuration of the connected Sensors. 1. Press the “Run” button to start the reading of the Sensors

Figure 9 Config Tool - Monitor Mode

2. Temperature values will appear as shown below

The Sensors will be read every 2 seconds; no other operations can be performed whilst the monitor is in Run mode.

3. When you are sure that all sensors are functioning correctly, click “Stop” to finish. Stop MUST be pressed before any other programming functions can take place. 4. This concludes the configuration process and should now be repeated for all Datacards on the system. Page 23 of 32

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Exertherm® Datacard Configuration & Commissioning Tool Guide

4.5

DATACARD CONFIGURATION TOOL SUPPORT By clicking on the about ‘Help’ button, you can view software version number and build date. In addition, for help regarding the Exertherm Datacard Config Tool please see the direct links to either the website or email address which is provided for technical support.

mailto: [email protected]

Figure 10 Datacard Config Tool Support

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Exertherm® Datacard Configuration & Commissioning Tool Guide

5.

CONNECTION TO A FRONT-END APPLICATION The following information will be required should the system be connected to a front-end monitoring system other than Exertherm LoadMap.

5.1

MODBUS FUNCTIONS & REGISTERS:

NODE RANGE The Datacard accepts a node address range of 1…247 which can be programmed by the configuration software provided.

DETAILS OF MODBUS REGISTERS 001…008 Field values of channel 1 through 8 are contained in 16bit registers. The register values require a 0.1 multiplier to be used when reading via a SCADA system to provide a true temperature reading. The temperature value can range from -50°C to +300°C depending on the used Sensor. A negative temp value will be indicated by setting the most significant bit of the 16bit register to 1. The measurements are updated constantly and can be retrieved using the function codes 03 or 04, (read input or holding register, both will deliver the same output). In Modbus terms referred to as 30001….30008 and 40001….40008. Example: measured ΔT = +2.5°C 1) 2)

therefore register content = 25, calculation 25 x 0.1 = ΔT 2.5°C

Example: measured ΔT = - 0.5°C 3) 4) 5)

therefore register content = 65530, Invert register and add sign: Xor(65530) x -1 = -5 and; finally calculation -5/10 = ΔT-0.5°C

SIGNED INTEGER If possible all values in the Register should be read as a ‘signed integer’. Then if the value is read as a signed integer the signing is carried out automatically by the system reading the registers.

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Exertherm® Datacard Configuration & Commissioning Tool Guide

6.

TROUBLESHOOTING

6.1

DATACARD TROUBLESHOOTING GUIDE When the LEDs are sequentially flashing (R-G-Y-R-G-Y...) the module has detected a failure during its self-test procedure. One of 4 errors may exist: 1) Cannot establish Comms – replace any cables or converters with Exertherm product (PN# 800447) 2) Node address out of range, reset to factory stored values (see Factory reset). 3) Under or over voltage of power supply, check power to connections. 4) Module not programmed/initialized, return factory values (see Factory reset). If after carrying out these troubleshooting steps, the device is still not functioning, and the LED’s are still sequentially flashing (R-G-Y-R-G-Y...). Then the Datacard must be returned for testing and replacement (under warranty if applicable). After powering up the module all 3 LEDs will light up shortly indicating the self-test procedure. It will also allow the user to check the proper operation of the LEDs. After this start-up sequence the yellow LED should pulse indicating proper operation mode.

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Exertherm® Datacard Configuration & Commissioning Tool Guide

7.

TECHNICAL DATASHEETS

7.1

DATA SHEET – IR SENSOR GAIN MATRIX

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7.2

EXERTHERM INSTALL & CONFIGURATION RECORD Project Name: Customer: Section Ref:

Modbus Address:

Serial No.:

C H A N N E L

DATACARD CHANNELS C C C H H H A A A N N N N N N E E E L L L

C H A N N E L

C H A N N E L

C H A N N E L

C H A N N E L

1

2

5

6

7

8

3

4

Section Reference Phase Reference Sensor Type No Sensor IR.EM-06.SC – Delta T IR-01 Absolute Cable EM – Delta T Cable – Absolute IR.EM-06.SC Only Busbar Size Mounting Distance Gain Factor Used Factory Acceptance Test Initial Value Heat Tested Reading

Datacard FAT: Accepted / Signed Installer: Date:

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Client Rep. Date:

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