ISensIO Manual Rev 1.3

vMonitor Wireless System – Installation, Maintenance and Troubleshooting Rev. 1.2 Page 1

vMonitor Wireless Monitoring

System Installation, Maintenance and Troubleshooting

vMonitor

2

Contents

Conventions Used in This Manual ............................................................................................................ 5

Special Instructions for Safe Use .............................................................................................................. 6

System Overview ..................................................................................................................................... 7

The iSens ................................................................................................................................................ 8

iSens Features ............................................................................................................................ 9

iSens Printed Circuit Board ......................................................................................................... 9

Radio Specifications...................................................................................................................10

Safety ........................................................................................................................................11

Shipping Instructions .................................................................................................................12

Default Shipping Configuration ..................................................................................................12

Handling and Storage Instructions .............................................................................................12

The i-Recv ..............................................................................................................................................13

Specification ..............................................................................................................................14

Power Requirements .................................................................................................................14

vMonitor User Interface .........................................................................................................................15

Set-Up ................................................................................................................................................... 16

Install the i-Config User Interface ...........................................................................................................16

Project Hierarchy ...................................................................................................................................16

Project Set-Up ...........................................................................................................................17

Create a new site .......................................................................................................................18

Add i-Recv .................................................................................................................................19

Add I-SENSs ...............................................................................................................................20

Configuring an i-Recv .............................................................................................................................21

Logical Configuration .................................................................................................................23

Logical i-Recv RS485 Serial Connection ......................................................................................26

Configuring iSens ...................................................................................................................................30

Configuration i-Sens procedure ..............................................................................................................33

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Uploading Firmware to i-Sens ....................................................................................................33

Configure i-Sens ........................................................................................................................37

Configure the ID of iSens ...........................................................................................................39

Changing the Serial Number of iSens .........................................................................................42

Configure the Sleep Time of i-Sens ............................................................................................45

Changing the Report Factor of i-Sens .........................................................................................47

Reading Raw and EU values of i-Sens AI Channels for Voltage/Current Input .............................50

Configure i-Sens AI Channels for Raw values Calibration ............................................................53

Configure i-Sens AI Channels for Engineering Unit(EU)values Calibration ...................................58

Configure i-Sens AI Channels for Voltage Input-Output Calibration ............................................61

Configure i-Sens AI Channels for Current Input-Output Calibration ............................................64

Configure i-Sens Digital Input Channels .....................................................................................67

Configure i-Sens Digital Output Channels ...................................................................................69

Configure i-Sens Analog Input Channels for Report By Exception(Alarms) ..................................73

Configure i-Sens Digital Input Channels for Report By Exception(Alarms) ...................................77

Jumper Settings for iSens Rev 0.0 ..............................................................................................81

Voltage Sensor Mode ................................................................................................................82

Current Loop Sensor Mode ........................................................................................................82

Configuring the iSens to support 4-20mA sensors ......................................................................83

4.0 Installing a iSens .............................................................................................................................. 84

Pre-installation ......................................................................................................................................84

Enclosure Mounting Configuration .........................................................................................................85

CONNECTING THE iSens Board to the Power Source ..................................................................86

Monitoring a Project ............................................................................................................................. 91

i-Recv Diagnostics Report .......................................................................................................................92

Network Info Tab.......................................................................................................................92

Triggered Calculations Tab.........................................................................................................92

Network Alarms Tab ..................................................................................................................92

WMP Msg Status .......................................................................................................................92

Network RF Status .....................................................................................................................92

Debug .......................................................................................................................................92

i-Report .....................................................................................................................................93

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i-Chart .......................................................................................................................................94

Maintenance ......................................................................................................................................... 95

Troubleshooting Guide .......................................................................................................................... 96

New Firmware, i-Recv ............................................................................................................................ 97

Checklist ................................................................................................................................................ 98

Mapping Register ................................................................................................................................ 100

5

Conventions Used in This Manual

This manual uses consistent conventions to help you identify items throughout the documentation. The

following table summarizes these conventions.

Convention Use

Bold

� Window and menu items

� Technical terms, when introduced

Italics

� Book and CD-ROM titles

� Variable names and values

� Emphasized words

Fixed Font

� File and folder names

� Commands and code examples

� Text you must type

Blue Text

� Cross-reference jumps (in PDF)

� URLs

SMALL CAPS � Keyboard button names, such as ENTER

The Note icon points out additional useful information. For example, notes are generally used to point out links to additional information.

The Tip icon provides tips for performing specific operations. For example, tips are generally used to point out shortcuts.

The Caution icon alerts you to all relevant safety points.

6

Special Instructions for Safe Use

Any disregard of these safety instructions may void the ATEX certification.

Do not install or service without a gas test.

Do not open when explosive gas is present.

This equipment is intended for use in a Zone I classified area. Use only in accordance with ATEX specifications as listed in EN60079-15, EN50014-1998 and EN50018-2000.

Installation shall comply with instructions EN60079-14.

Use cable color coding in accordance with ATEX and NEC specifications. Do not use a blue cable jacket (i).

7

System Overview

The vMonitor Wireless Monitoring System (VWMS) enables centralized monitoring of sensors placed

throughout a field of work. The system is based on three components including vMonitor Remote

Terminal Units (iSens), i-Recv and the i-Configx user interface. iSens gather information from sensors

and relay the information to the i-Recv, wirelessly. The i-Recv stores the information in pre-allocated

Modbus registers and serves as the communication hub. The i-Recv provides the stored information

directly to an Electronic Flow Computer, an RTU, a PLC or a process automation network using a

Modicon Modbus Protocol and an RS 485 serial interface. The i-Recv can also pass the information

stored in any of the Modbus registers to the 3 discrete analog and 2 discrete digital outputs.

Additionally, the i-Recv can also provide information directly to the system operator during normal

operation via the i-Config user interface, which is also used for system configuration, maintenance and

diagnostics.

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The iSens

The iSens is a remote data transmitter. It mounts in the field, gathers sensor data, packetizes the

information and transmits it using a ZigBee spread spectrum radio. The radios comply with FCC part

15.247 regulations, and operate in either the 900 MHz or 2.4 GHz range, depending on the option

ordered. This sensor data message will be broadcast to an i-Recv and will be stored in pre-assigned

Modbus registers. The data collected from the sensors can be replicated on the i-Recv’s discrete

outputs or it can be communicated from the Modbus registers over an RS485 connection to an attached

Flow Computer, RTU or PLC.

iSens are designed to operate on 12 volts which can be supplied by the included battery or by an

external power supply. In its standard configuration, safe, multi-year battery life can be expected.

The iSens will power sensors requiring a 10 to 15 volt supply. Sensors are connected by means of

terminal blocks.

The iSens powers up at a user determined interval, and after a brief settling period, samples the sensor

outputs.

Each iSens has a unique ID and is configured to work with a specific i-Recv, based on its unique ID.

Installation of the i-Recv must be in accordance with the instructions in this manual to ensure

conformance to UL, ATEX and FCC standards. Deviations from these instructions may compromise

conformance and safety.

9

iSens Features

• Industry standard micro-controller

• 12 Volt battery standard, user supplied external 6 to 12VDC supply optional

• Analog input channels for voltage or current sensors

• 10V and 15V supply available to power sensors

• When supporting mA sensors, the ISENS can provide a regulated voltage source of 6.67v, 10v or

15v and can provide 200mA or 150mA to power sensors, respectively.

• Two Opto-Isolated 3-24 volt, AC or DC digital inputs

• Two hardware interrupts

• One hardware interrupt input

• Internal temperature and battery monitoring

• Two Digital Outputs, one can support a solid state relay requiring up to 350mA

• Low power and sleep operating modes

• Option of a 900 MHz or 2.4 GHz Zigbee radio

• Temperature range of –40°C to +85°C

• Wake up timer can be programmed to operate from 0.008 seconds to 18 hours

• RS232 Interface allows serial connection with a computer for configuration and for updating

firmware

iSens Printed Circuit Board

Analog I/O

RS 232

Interface

Power

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Radio Specifications

900MHz 2.4GHz Performance

Indoor/Urban Range w/2.1 dipole antenna

Up to 1500 ft

Outdoor RF line-of-sigh range

(w/2.1 dB dipole antenna)

Up to 2 miles

Outdoor RF line-of-sight Range w/ high-gain antenna

Up to 5 miles

Transmit Power Output 100 mW (20 dBm)

Interface Data Rate (software selectable)

110-57600 bps (including non-

standard baud rates)

Throughput Data Rate

9,600 bps

19,200 bps

RF Data Rate

10,000 bps

20,000 bps

Receiver Sensitivity

-110

dBm

-107 dBm

Power Requirements

Supply Voltage 5V (± 0.25V) regulated

Receive Current 50 mA

Transmit Current 140 mA

Power-Down Current < 26 µA

General

Dimensions 1.600” x 2.825” x 0.350” (4.06 cm x 7.18 cm x 0.89 cm)

Weight 0.8 oz (24 g)

Operating Temperature

0-70 C° (Commercial) or -40 to 85 C° (Industrial)

Antenna Options

RPSMA, MMCX, or Wire Antenna

Networking and Security

Operating Frequency ISM 902-928 MHz

Supported Network Topologies

Peer-to-Peer (no master/slave dependencies), point to point, point to multi-point, multi-drop

Number of Channels (software selectable)

7 Frequency Hopping Channels

Network Filtration Layer

VID, Channel, Destination Address

Agency Approvals

FCC Part 15.247 Industry Canada (IC)

OUR9XSTREAM 4214A-9XSTREAM

Performance

Indoor/Urban Range w/2.1 dipole antenna

Up to 600 ft

Outdoor RF line-of-sight Range

(w/2.1 dB dipole antenna

Up to 1 mile

Outdoor RF line-of-sight Range w/ high-gain antenna

Up to 3 miles

Transmit Power Output 50 mW (17 dBm)

Interface Data Rate (software selectable)

110-57600 bps (including non-

standard baud rates)

Throughput Data Rate 9,600 bps

19,200 bps

RF Data Rate 10,000 bps

20,000 bps

Receiver Sensitivity -105

dBm

-102

dBm

Power Requirements

Supply Voltage 5V (± 0.25V) regulated

Receive Current 80 mA

Transmit Current 150 mA

Power-Down Current < 26 µA

General

Dimensions 1.600” x 2.825” x 0.350” (4.06 cm x 7.18 cm x 0.89 cm)

Weight 0.8 oz (24 g)

Operating Temperature

0-70 C° (Commercial) or -40 to 85 C° (Industrial)

Antenna Options

RPSMA, MMCX, or Wire Antenna

Networking and Security

Operating Frequency ISM 2.4000-2.4835 GHz

Supported Network Topologies

Peer-to-Peer (no master/slave dependencies), point to point,

point to multi-point, multi-drop

Number of Channels (software selectable)

7 Frequency Hopping Channels

Network Filtration Layer

VID, Channel, Destination Address

Agency Approvals

FCC Part 15.247

OUR-24XSTREAM

4214A 12008

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Safety

� WHILE HANDLING THE PRINTED TRANSMITTER CIRCUIT BOARD, ALWAYS USE

ELECTROSTATIC-FREE GLOVES AND CONNECTORS.

� ALWAYS USE PROPER PROTECTIVE EQUIPMENT WHILE MAINTAINING THIS DEVICE. EYE PROTECTION IS A MUST; THEREFORE, ALWAYS USE GOGGLES

WHILE MAINTAINING THIS DEVICE.

� ENSURE THAT ALL WIRING ENTERS THE ISENS ENCLOSURE THROUGH THE WEATHERPROOF CONDUIT AND CONDUIT FITTINGS, AS PER SECTION 501.4 OF

THE NATIONAL ELECTRIC CODE.

� EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR NORMAL OPERATION AND CAN NULLIFY THE CERTIFICATION FOR THE USE OF THIS

EQUIPMENT FOR CLASS 1, DIVISION 2 APPLICATIONS.

� EXPLOSION HAZARD - DO NOT REPLACE BATTERIES UNLESS THE POWER TO THE UNIT, AND ALL OTHER DEVICES CONNECTED TO IT, HAVE BEEN

SWITCHED OFF.

� EXPLOSION HAZARD - DO NOT REPLACE THE BATTERIES IN A HAZARDOUS AREA. MAKE SURE THE AREA IS UNCLASSIFIED AND KNOWN TO BE NON-

HAZARDOUS.

� EXPLOSION HAZARD - THE SHORTENING OF THE TERMINALS OF ANY BATTERY CAN RESULT IN AN EXPLOSION OF THE BATTERY. DO NOT PERMIT THE TERMINALS OF THE PROVIDED BATTERY TO SHORTEN UNDER ANY

CIRCUMSTANCES.

� ALWAYS MAKE SURE TO OBSERVE DC POLARITY BEFORE CONNECTING

EXTERNAL POWER SUPPLY TO THIS DEVICE.

� EXPLOSION HAZARD - ALWAYS USE UL/CE APPROVED CLASS 2 POWER SUPPLY

AS AN EXTERNAL POWER SOURCE WHEN NEEDED, WITH NO EXCEPTIONS.

� EXPLOSION HAZARD - DO NOT MAKE OR BREAK CIRCUIT CONNECTIONS WHILE

POWER IS ON UNLESS THE DEVICE IS IN A NON-HAZARDOUS AREA!

� EXPLOSION HAZARD - ALWAYS TURN THE ON-OFF TOGGLE SWITCH TO THE OFF POSITION AND DISCONNECT THE POWER SOURCE PRIOR TO ANY

MAINTENANCE WORK!

� TO PREVENT STATIC ELECTRICAL SPARKS, ALWAYS CLEAN THE UNIT WITH A DAMPENED CLOTH. NEVER USE DRY CLOTH.

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Shipping Instructions

Prior to shipping, ensure that the POWER SWITCH SW1 on the iSens board is in the OFF position.

Default Shipping Configuration

Prior to shipping, ensure that the SW1 switch on the ISENS is securely in the OFF

position.

The iSens is typically supplied with one UL approved battery pack. For shipping, the battery power

harness is disconnected from the power connector of the iSens main board to preserve battery life

during transit. The iSens will operate on power supplied by the battery pack or external DC line power.

Handling and Storage Instructions

The iSens transmitter unit is supplied with a NEMA 4X/7 explosion-proof die-cast

aluminum enclosure. Units with enclosures weigh approximately fourteen (14) pounds,

and do not need any special handling equipment.

While handling the printed transmitter circuit board, always use electrostatic-free gloves and connectors.

The operating and storage temperature limits for the ISENS transmitter are shown below. Always

operate, test, handle, and store equipment within the specified limits:

Operating Temperature -40° F to 185 °F (-40 to 85 °C)

Storage Temperature -40°F to 185 °F (-40 to 85 °C)

Operating Humidity 5 to 90% RH non-condensing

Electro-Static Discharge can damage the iSens boards and can cause complete or intermittent failure, observe ESD

prevention procedures when handling these boards. Also follow these ESD preventive tips when working with the boards:

1. Wear Electro-static gloves or wrist-straps, be sure that you’re properly grounded, before handling the board.

2. When transporting the board, always have the board in a protective static-free bag or sleeve.

3. If the board is separate from the enclosure, always store the board in its protective static-free bag or sleeve.

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The i-Recv

The i-Recv is the gateway between the process domain and the Flow Computer, PLC or RTU. The i-Recv

receives sensor data wirelessly from the iSens, acts as a data concentrator, and stores the data received

in Modbus registers. The i-Recv can provide the date to an attached Flow Computer, PLC or RTU over

discrete outputs and/or over a Modbus interface.

The i-Recv emulates an RTU with one side receiving data from the wireless sensor network and on the

other side presenting that data to the control system.

The i-Recv is located in a central position with respect to all associated iSens. Each standard i-Recv can

support up to 10 iSens, while the advanced i-RecvII can support up to 100 ISENS. Each i-Recv has a

unique i-Recv ID number, and will support all iSens which are configured to communicate with that

IRecv. All Data received from iSens which have a matching i-Recv number will be collected and mapped

to local Modbus registers. A SCADA system, Flow Computer, RTU or PLC can poll the designated registers

for each iSens over the RS-232/RS-485 serial port using Modbus RTU protocol.

The i-Recv is a logical database for all the associated iSens. The i-Recv will have a Modbus register set

which mirrors Modbus registers in each associated iSens. An i-Recv supporting 10 iSens will have 11

Modbus register sets; one for each iSens’s data and engineering units and one for its own Modbus

register data.

In the standard configuration, iSens are configured to push samples to the i-Recv on a periodic or

interrupt driven basis. This configuration extends the battery life significantly. In the push mode, the

iSens will operate in battery conserving mode and will wake on the preconfigured interval, sample the

local sensors, accumulate the designated number of samples and push a message to the i-Recv when the

designated number of samples is collected. It may push a message sooner if transmission is triggered by

either a hardware interrupt, if configured by percentage changes or by reaching predetermined

minimum or maximum levels. When the iSens is in Poll mode, the unit is continuously powered,

sampling the I/O and waiting for the i-Recv to request data.

The i-Recv has built-in network diagnostics and using the i-Config, the operator can look at which iSens

are registered, the time the last message was received, and other information as described more fully in

the trouble shooting section of this manual.

The following sections of this manual describe how to create configuration files, how to upload

configurations to the i-Recv and iSens using the i-Config software and how to install the system. In the

event that i-Recv and iSens operation system updates are provided, instructions for uploading the new

operating systems are provided at the end of this document.

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Specification

• Industry Standard micro-controller

• Supply voltage required: 7-34 VDC

• Radio signal strength channel

• Internal temperature channel

• Two Opto-Isolated 3-24 volt, AC or DC digital inputs

• Three analog 9 outputs than can emulate 0-5v or 4-20mA sensors

• One RS232/RS485 serial interface port

• Plug-in radio that can operate at a frequency of 900 MHz or 2.4 GHz

• Temperature range of –40°C to +80°C

Power Requirements

The i-Recv has two power input terminals. They are both used in critical applications where the i-Recv

will be powered by a primary as well as a back-up power source. Either power source can be used as

the primary. The microcontroller will select the source operating at the higher voltage as the primary

supply.

The i-Recv will work on unregulated DC power from 7-34 VDC.

Current consumption of the i-Recv is:

Nominal Board current including radio in listen Mode: 72 mA

Power spike in transmit mode with all I/O active: 160 mA

15

vMonitor User Interface

The i-Config User Interface is a tool which allows the operator to configure iSens and i-Recv. It enables

basic data monitoring and provides access to network diagnostics one “Project” at a time.

At set up, the operator will “create” a Project. The i-Config can then be used to configure, monitor and

troubleshoot the project. Multiple projects can be created, saved, reopened, used and saved again.

Once a Project has been created, the i-Config will be used to upload the configurations into the

associated i-Recvs and iSens. Once the configurations have been uploaded into its i-Recvs and iSens, the

system can be bench tested before deployment to the field.

If you select a specific i-Recv in the Network and double click the icon in the Project Explorer Pane, a

tabular report will appear in the middle of the application screen displaying the i-Recv name and

showing basic data operational and diagnostics data for the associated iSens.

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Set-Up

Set-up requires the creation of a Project and uploading the configurations into each i-Recv and iSens.

Installation requires configuring the jumpers and switches, mounting the iSens, attaching sensors and

power, configuring the jumpers and switches on the i-Recv, installing the i-Recv, and making a

connection to either the Flow Computer, RTU or PLC.

Install the i-Config User Interface

The i-Config is a configuration, monitoring and diagnostics tool. It allows the user to set up a Project’s

hierarchy and configure the i-Recv and iSens used in the Project. The i-Config is provided in a self

extracting executable file. Download the latest version of the i-Config from the support website or copy

it from the CD provided. Double click on the file and follow the sequence of instructions to install the i-

Config.

Project Hierarchy

To set up a Project the user begins with a Project name. Under the Project, individual sites each

representing a lease or field are established and assigned one i-Recv. Each standard i-Recv can support

up to 10 vMonitor Remote Devices such as the iSens.

17

Project Set-Up

• Launch the i-Config User Interface

• Click on File

• Click on New Project

• Enter a Project Name

18

Create a new site

• Right Click on the name of your new project.

• Click on add new

• Slide over to Site

• Click on Site

• Enter a Site Name

• Click Ok

Multiple sites can be created under your project.

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Add i-Recv

Once the sites are created, a corresponding i-Recv must be created. There is a one-to-one relationship

between Sites and i-Recv.

• Right click on a site

• Slide to add new

• Slide to i-Recv

• Click on i-Recv

• Enter a name for this i-Recv and check a numbered box to designate this i-Recv’s Modbus slave

ID.

• Click Ok

Each i-Recv must be given a unique Modbus slave ID.

The iSens which communicate with this i-Recv will automatically be given the same ID when their

configuration is uploaded to them.

20

Add I-SENSs

Once the sites i-Recv’s are created, iSens can be added. Each standard i-Recv can support up to 10

iSens.

• Right click on an i-Recv.

• Slide to add new

• Slide to iSens

• Click on iSens

• Enter a name for this ISENS and check a numbered box to designate this iSens Modbus slave ID.

• Click Ok

Each iSens must be given a unique Modbus slave ID.

21

Configuring an i-Recv

Configuring an i-Recv includes setting up the hardware and uploading the configuration.

The default configuration for the i-Recv will include the latest revision of the firmware and certain

defaults including the following parameters:

Serial port Configuration: 9600, 8N & 1

MODBUS slave address: 1

Starting associated iSens address: 100

The serial port on the PC running the i-Config User Interface must be configured to match the above

communication parameters in order to upload the configuration to the i-Recv.

22

Jumper Settings for i-Recv Rev 0.0

All jumper and switch will be in the default settings as shown in the table below.

Jumper

Number

Setting Description

JP8

1-3 & 2-4 3-5 & 4-6

Selection of RS-232/RS-485 jumper

Enable RS-232 Communication Enable RS-485 Communication

JP9

1-3 & 2-4

3-5 & 4-6

Selection of RS-232/RS-485 jumper

Enable RS-232 Communication

Enable RS-485 Communication

PSW1 1-ON

1-OFF

2-ON

2-OFF

Set to ON (OPEN) to read AO Voltage on V01

Set to OFF (CLOSE) to read AO Current on Ai1

Set to ON (OPEN) to read AO Voltage on V02

Set to OFF (CLOSE) to read AO Current on Ai2

PSW2 1-ON

1-OFF

2-ON

2-OFF

3 -ON

3-OFF

4-ON

4-OFF

Set to ON (OPEN) to read AI Voltage on A1

Set to OFF (CLOSE) to read AI Current on A1







SW1 Power Switch

SW2 ON

OFF

10v/15v power to sensors (Push Towards SW1- 10V)

SW3 Restart board trigger

SW4 Reset/Download Switch

23

Logical Configuration

Select the i-Recv in the Project Explorer pane. Open the Properties pane following the directions below.

The Properties pane will show the properties of the selected i-Recv. Three tabs are visible: Basic,

Advanced and Wire Replacement. These tabs allow you to configure all of the i-Recv’s parameters.

• Click on View

• Slide down to Properties

• Click on Properties

The Basic tab allows you to configure communication parameters.

The Advanced tab enables calibration.

The Wire Replacement tab allows you to map data from any sensor on any supported iSens to any of the

discrete outputs on the i-Recv.

• Enter values or accept the defaults for the configuration parameters.

24

Save the project changes by going to File > Save. After saving the project, all

network devices whose configurations have not yet been uploaded are so noted

with a red arrow indicator.

• Connect the i-Recv to the configuration PC using the cable provided. The cable should be

connected to the correctly configured serial port on the PC and to JP7.

• Connect JP1 or JP2 on the i-Recv to the local power supply.

• Right click on the i-Recv you wish to configure

• Slide to Upload Configuration

• Click On Upload Configuration

If you receive the Session has expired message at this point, log in as the

Administrator on your PC and repeat Step 8.

The Connection Settings dialog box is displayed. This enables you to configure your PC to match the

configuration of the attached i-Config.

The Connection Type is set to RTU by default to configure the i-Recv when it is physically connected to

the configuration PC which is running the i-Config User Interface software.

• Select the COM Port you are using on your PC

• Use the default Baud Rate, 9600

• Data Bit, Parity and Stop Bit should be set to 8, N and 1

25

• Select the configuration to be uploaded

• Click OK.

The configurations will be uploaded to the device.

26

Logical i-Recv RS485 Serial Connection

To poll the i-Recv on the RS485, change the jumpers on JP8 & JP9 as shown in the Figure below. Connect

the RS485+, RS485- and the Ground cables to COM2.

The iRecv RS485 serial port has the following configuration:

9600 baud

8 Data Bits

None Parity

1 Stop bit

Register Mapping for Raw Data

The i-Recv can support 10 i-Sens with ID 100-101. The Raw & Engineering Unit Datas of each of the i-

Sens are mapped onto local registers of the i-Recv. The Raw Data for the three analog channels and the

battery channels can be polled on i-Recv registers:

27

[Slave ID 1]

[Input Register] [Display Type- Unsigned Integer]

28

Register Mapping for EU Data [Slave ID 1]

[Input Register] [Display Type- Swapped Float]

29

Register Mapping for Signal Strength The signal strength gives a measure of the quality of the wireless communication link between the iSens

and the iRecv. It has a range of -36db to 102db with -36db representing the best or highest signal

strength and -102db representing the lowest signal strength. This data can be read from the following

registers:

[Slave ID 1]

[Input Register] [Display Type- Unsigned Integer]

Register Mapping for Sleep Interval The sleep time for each iSens can be changed through the iRecv. All the changes would be sent to the

iSens and would take effect only in the next communication. The sleep interval (in seconds) could be

changed through the following registers:

[Slave ID: ID of the iSens]

[Holding Register] [Display Type- Unsigned Integer]

30

Configuring iSens

Configuring an iSens includes setting up the hardware and uploading the configuration.

The default configuration for the iSens will include the latest revision of the firmware and certain

defaults including the following parameters:

Serial port Configuration: 9600, 8N & 1

MODBUS slave address: 1

Starting associated iSens address: 100

The serial port on the PC running the i-Config User Interface must be configured to match these

communication parameters in order to upload the configuration to the i-Recv.

Select the iSens in the Project Explorer pane. Open the Properties pane following the directions below.

The Properties pane will show the properties of the selected iSens. Three tabs are visible: Basic,

Advanced and Alarm. These tabs allow you to configure all of the iSens’s parameters. Default

parameters will be displayed and can be changed or will be accepted as the default.

• Click on View

• Slide down to Properties

• Click on Properties

The Basic tab allows you to configure communication parameters and timing as well as to select the

electrical characteristics of the 3 analog inputs, 3 digital inputs and 2 digital outputs.

The Advanced tab enables calibration.

The Alarm tab enables you to set minimum, maximum and percentage change that would trigger a

sample to be taken and sent.

Each of the 3 analog input channels can be separately configured to support a voltage out sensor or a

mA sensor. All channels will have the same sampling and transmission rates. Sampling rates can range

for 2 per second to one every 18 hours. Sampling and transmission frequency will impact battery life.

Each of an iSens 3 analog channels can provide power to a voltage out our current out sensors.

Alternatively, external power can be used. Low Power voltage sensors, powered by the iSens, are

typically selected because of the simplicity of the installation and the excellent battery life that can be

accomplished with appropriately set timers and triggers.

iSens will run on 6 to 12 VDC.

31

The iSens will go to sleep and wake-up at a programmed time interval and repeat the process. The red

LED will come on when the iSens is collecting and sending data and will go off when the iSens is in SLEEP

mode.

Reference - Basic Tab

The following table lists the configuration menu options and defaults under the Basic Tab.

Menu Option Default Value

General

Name Primary Slave Primary Slave Message Setting Sleep interval

Hour Time Offset to sync Reporting Message Ack. Time out Report Transmit Factor Time Setting Sensor Settling Time

Modem Settling Time (ms) Delay Before Modem Shutdown Delay between message Transmission Delay Before Sleeping Time Zone

Com Settings Baud rate Parity Stop Bits Data bits

Analog Input Channels Channel 1 Channel 2 Channel 3 Channel 4

Digital Input Channels Channel 1 Channel 2 Channel 3 Channel 4

Buffer Info Analog Output Channels Channel 1 Channel 2 Channel 3

Channel 4

Slave ID: The i-Recv Modbus Slave ID

Operation Mode: The unit’s mode of operation: Battery Conserving Sleep or Continuously Powered

32

Reference - Advanced Tab

The following table lists the configuration menu options and defaults on the Advanced Tab.


Channel Calibration Channel 1 Smoothing Factor Resistor Value Raw Min count

Raw Max count Flow Min count Flow Max count Calibration Low count Calibration High count

Engineering Min. Engineering Max Channel 2 Channel 3 Channel 4

AO Calibration Coefficient Factor Constant

Alarm Tab

The following table lists the configuration menu options and defaults on the Alarm Tab.


AI Channel Alarms Channel 1 Raw Count Min (0 No Alarm) Raw Count Max (0 No Alarm)

Percent Change Channel 2 Channel 3 Channel 4

33

Configuration i-Sens procedure

Uploading Firmware to i-Sens

Firmware can be uploaded to i-Sens by either I-CONFIG or WSD (Windows Serial

Downloader).

A. Through ICONFIG

The default configuration of the i-Sens will include the latest revision of the firmware and

some other parameters.

In case if you want a particular firmware to be loaded / reloaded the firmware in the i-Sens then :

Download the program/firmware. This requires a three stage process, with the first two

stages used to prepare the board for downloading the firmware. This involves resetting the

controller on the board and installing the serial number of the board. The final stage is

downloading the actual firmware.

Step 1: Power up i-Sens. Connect the Serial Cable (RS-232) to the serial port of i-Sens

and your PC’s COM port.

Note 1: Make sure that the 1st switch of the PSW1 block (near to serial port) on i-Sens is

not pushed towards “Open”.

Now the i-Sens is in Configuration Mode.

34

Step 2: To reset controller, hold SW3 and turn SW1 OFF and ON, then release SW3.

Step 3: Open ICONFIG, and load the project folder (File- Load Project).

Step 4: Right-Click on the iSens and select the Upload Firmware option.

Step 5: Open the folder containing the latest firmware and select the iSens.HEX and

click Open.

Step 6: Select the COM port that corresponds to your computer port and click OK.

Step 7: It will display OK. You have completed the download of the firmware.

Step 8: If you want to check firmware on ICONFIG, you have to double click on iSens

again to see the changes.

35

Step 9: It will be shown as tabs in the ICONFIG main window. Connect using the green

button as shown before.

Step 10: i-Sens is now ready to be configured.

You can also view the firmware version of i-Sens on HyperTerminal.

Step 11: Connect to HyperTerminal and turn the board OFF and ON to reboot the

controller.

Step 12: HyperTerminal will display the version number of the firmware and it will say

“configuration loaded ok”. Disconnect from HyperTerminal.

Note 2: Turn the 1st switch of the PSW1 block on i-Sens to “Open” position after you upload any

firmware in order for the i-Sens to communicate with the iRecv.

B. Through Windows Serial Downloader (WSD)

WSD is a tool for downloading firmware or to reset boards.

Step 1: Connect the Serial Cable (RS-232) to the serial port of i-Sens and your PC’s COM

port.

Note 1: Make sure that the 1st switch of the PSW1 block (near to serial port) on i-Sens is not

pushed towards “Open”.

Step 2: Click on the Configuration button, and select the appropriate Port. Select

correct options for Erase Mode, Download Mode. Check the box for “Prompt

me for files when downloading”. Then Click OK.

36

Step 3: Reset i-Sens controller by holding SW3 and turn SW1 OFF and ON and release

SW3.

Step 4: Click the Reset button on WSD.It will show you the message,“Reset complete”.

Step 5: Click on Download button and a new window will pop-up to select the firmware

file you want to upload to i-Sens.

Step 6: Select the file and “Open” it. The code will be loaded into the i-Sens controller

and the message “Download successful” will show.

Then the i-Sens is ready to be configured.

Step 7: In ModBus Poll, check the firmware of the i-Sens, poll Input Registers: 4 -5

(Float Inverse-Data type) with i-Sens ID=245.

Note 2: In Configuration mode, i-Sens ID=245.

37

Configure i-Sens

Step 1: In ICONFIG, select the i-Sens and click on View.

Step 2: Click on Properties

Step 3: The Basic tab allows you to configure communication parameters, timing and to

select the electrical characteristics of the 3 analog inputs, 3 digital inputs and 2

analog outputs.

Step 4: The Advanced tab enables calibration.

Step 5: The Alarm tab enables you to set minimum, maximum and percentage change

that would trigger a sample to be taken and sent.

38

Step 6: Sampling rates can range from 2 per second to one every 18 hours. Sampling

and transmission frequency impacts battery life.

Step 7: Each of the i-Sens’ 3 analog channels can provide power to a Voltage out or

current out sensors, alternatively external power can be used.

Step 8: The i-Sens will go to sleep and wake-up at a programmed time interval and

repeat the process.

Step 9: The red LED will be ON when the i-Sens collects and sends data and will go

OFF when the i-Sens is in SLEEP mode.

Basic Operation

Turning the device ON with the jumper switch JP12 causes the following actions:

1) The device is powered and booted up as evidenced by the "VCC“ Red LED.

2) The device then goes into the data acquisition mode, where the sensors are

powered and the inputs are sampled.

3) The transceiver then transmits data to the Gateway/Data Concentrator.

4) The device goes into power-saving mode. The Red LED is now off. The unit is

now in sleep mode.

5) Once the unit comes out of sleep mode after the specified interval, the unit will

39

follow steps 2 to 4.

6) The unit can be forced to go into a transmit/active mode using the push button

switch SW4.

Caution: When the safety switch is turned off, external power is removed or the battery is disconnected, the device ceases to operate. When power is restored, normal operation is immediately resumed. No re-programming is required. Any accidental power-cuts during the first three steps may cause corruption of the iSens firmware. If external power is supplied, the battery will serve as back-up and power the device until power can be restored.

Configure the ID of iSens

We can configure the iSens parameters through ICONFIG or through corresponding Mapping

Registers of iSens using ModBus Poll.

By default, i-Sens Slave ID=100.

A. Through ICONFIG

Step 1: In ICONFIG, open the project and click on the iSens .It will show you the

Properties window. Click on the Basic tab.

Step 2: Slide onto Slave ID. Select it and pick any ID from the list and then click OK.

Step 3: Save it before you upload the settings to iSens. Before uploading the settings,

keep the iSens in Configuration Mode.

Note 1: Connect the Serial Cable (RS-232) to the serial port of iSens and your PC’s COM port.

Make sure that the 1st switch of the PSW1 block (near to serial port) on iSens is not pushed

towards “Open”.

40

Step 4: To upload the configuration, Right click on iSens and select upload

configuration via iSens.

Step 5: Perform the appropriate connection settings.

Step 6: Select the tabs values you want to upload. You can choose what tabs to configure

and upload.

Step 7: Once selected, all or partial, press OK to upload the configuration.

Step 8: After uploading configuration, Right click on iSens and select Properties.

Step 9: Click on Basic Tab and you can see the new Slave ID.

41

B. Through ModBus Poll

Step 1: Keep the i-Sens in Configuration Mode.

Step 2: Open a new MB Poll window with iSens ID=245.

Poll Holding Register: 123(Set new Slave ID) and write the ID which you want to keep for iSens.

Step 3: Click on the Send button to write it on the i-Sens’ controller.

Note 1: In Configuration Mode, iSens ID is 245.

Note 2: Data type of this register must be an Un-signed Integer.

42

When iSens wakes up the next time, it will register with the new ID.

Step 4: Poll Input Register: 07(Un-signed Integer) with iSens ID=245 and you can see

the current Slave ID after changing.

When iSens Communicates with iRecv using Radios, you can still poll the above registers with i-

Sens Slave ID.

Changing the Serial Number of iSens

A. Through ICONFIG

Step 1: Before entering the Serial Number through ICONFIG and uploading the settings,

keep the iSens in Configuration Mode.

Step 2: In ICONFIG, open the project and Right Click on the iSens.

Step 3: Select Set Points and slide onto i-Sens ID. Select it.

43

Step 4: Enter the password and the serial number. Click OK and it will be directly written

to the i-Sens.

Step 5: After writing new serial number, do settings for RS-232 Communication with

iRecv:

1) Turn the 1st switch of the PSW1 block on i-Sens to “Open” position and do the

settings for communication with iRecv.

2) Connect the Serial Cable to your PC’s COM port and 2nd

port of iRecv

(TX2+,RX2-,G). “Close” pins 1-2&3-4 of JP8&JP9 using jumpers as shown on pg.44

3) Insert the appropriate Radios on iRecv and iSens and Power ON both.

Note 1: It is better to Turn ON i-Sens after iRecv for better registration of i-Sens on iRecv.

44

The default configuration of the iRecv will include the latest revision of the firmware and

certain defaults including the following parameters:

a) Serial port Configuration:

Baud Rate-9600

Bits-8

Parity-None

Stop Bits-1

b) ModBus slave address: 1

c) Starting associated iSens address: 100.

Step 6: If you want to check on ICONFIG, you have to double click on iRecv and iSens

tags again to see the changes.


button, as shown before. You can see the new Serial Number of iSens as shown.

B. Through Modbus Poll


Step 2: Open a new MB Poll window with i-Sens ID=245.

45

Poll Holding Register: 141-142(Password Value)

Poll Holding Register: 143-144(New Hardware Serial Number).

Step 3: Enter Password and Serial Number using multiple register writing. Click on the

“Send” button to write the values into the i-Sens controller.

Note 1: In Configuration Mode, i-Sens ID will be 245.

Note 2: Data type of these registers must be Long Inverse.

Step 4: Poll Input Registers: 02 -03 (Long Inverse) with i-Sens ID=245 and you can will

the new Serial Number right away.

When i-Sens Communicates with iRecv using Radios, you can still poll the above registers with

i-Sens Slave ID.

Configure the Sleep Time of i-Sens

A. Through ICONFIG

Step 1: In ICONFIG, open the project and Click on the i-Sens. It will show you the

Properties window. Click on the Basic tab.

Step 2: Slide onto Sample Every (sec) option. Select and enter the time in seconds.

46

Step 3: Save it before you upload the settings to i-Sens. Before uploading the settings,

keep the i-Sens in Configuration Mode.

Step 4: To upload the configuration, Right click on i-Sens and select upload

configuration via i-Sens.

Step 5: Select the tabs values you want to upload. You can choose which tabs to

configure and upload.


You can check the new sleep time using ModBus Poll.

Step 7: Open a new MB Poll window with i-Sens ID= 245.

Poll Holding Registers: 03 (Un-signed Integer) and you can see the new sleep interval of i-Sens.

B. Through Modbus Poll


Step 2: Open a new MB Poll window with i-Sens ID=245.

47

Poll Holding Register: 03(Sleep Interval ) and write the time in seconds.

Step 3: Click on Send button to write it on the i-Sens ‘s controller.

Note 1: In Configuration Mode, i-Sens ID is 245.

Note 2: Data type of this register must be Un-signed Integer.

When i-Sens wakes up the next time, it will start reporting in the new Report Transmit Time.

Step 3: Poll the same Holding Register: 03 (Un-signed Integer) with i-Sens ID=245 and

you can see the new Report Time.

When i-Sens communicates with iRecv using Radios, you can still poll the above register with i-

Sens Slave ID.

Changing the Report Factor of i-Sens

A. Through ICONFIG

Step 1: In ICONFIG, open the project and click on the i-Sens. It will show you the Properties

window. Click on the Basic Tab.

Step 2: Slide onto Report Factor (sec) option. Click on that and enter the time in seconds.

48

Step 3: Save before you upload the settings to i-Sens. Before uploading the settings, keep the i-

Sens in Configuration Mode.

Step 4. To upload the configuration, Right click on i-Sens and select upload configuration via

i-Sens.

Step 5. Select the tabs values you want to upload. You can choose what tabs to configure and

upload.

Step 6. Once selected, all or partial, press OK to upload the configuration.

You can check the new Report factor using ModBus Poll.


Poll Holding Registers: 23 (Un-signed Integer) and you can see the new Report factor of i-Sens.

49

C. Through ModBus Poll (MB Poll)

Step 1 : Keep the i-Sens in Configuration Mode.

Step 2 : Open a new MB Poll window with i-Sens ID= 245.

Poll Holding Register: 23(Report Transmit Factor) and write the time in seconds.

Step 3: Click on the Send button to write it on the i-Sens’ controller.

Note 1: In Configuration Mode, i-Sens ID is 245.

Note 2: Data type of this register must be Un-signed Integer.

When i-Sens wakes up the next time, it will start reporting in the new Report Transmit Time.

Step 4: Poll the same Holding Register: 23(Un-signed Integer) with i-Sens ID=245 and

you can see the new Report Time.

When i-Sens Communicates with iRecv using Radios, you can still poll the above register

with i-Sens Slave ID.

50

Reading Raw and EU values of i-Sens AI Channels for Voltage/Current Input

A. Through ICONFIG


Properties window. Click on the Basic Tab.

Step 2: Select Analog Input Channels and under that select Channel 1.

Step 3: Slide onto Voltage/Current. Select Voltage/Current as you need.

You can do the same settings for all 3 analog channels and also for the battery channel.

Step 4: Save before you upload the settings to i-Sens. Before uploading the settings, keep

the i-Sens in Configuration Mode.




and upload.


Step 8: Give Inputs to the Analog Channels from source(Voltage/Current) through the

corresponding pins.

Note 1: Source +ve to AI+ of Channels. Source –ve to AI- of Channels.

Note 2: For Voltage Input, the switches of PSW2 block on i-Sens should be pushed towards

“open” position. For Current Input, make sure that switches of PSW2 block on i-Sens is not

pushed towards “open” position .

51

Step 9: After uploading configuration, do settings for RS-232 Communication with

iRecv :

1) Turn 1st switch of the PSW1 block on i-Sens to “Open” position and do the settings

for communication with iRecv.


port of iRecv

(TX2+,RX2-,G).“Close” pins 1-2&3-4 of JP8&JP9 using jumpers as shown before.

3) Insert appropriate Radios on iRecv and i-Sens and Power ON both.


Step 10: If you want to check on ICONFIG, double click on iRecv and i-Sens tags

again to see the changes.

Step 11: It will be shown as tabs in the ICONFIG main window. Connect using the

green button, as shown before. You can see the Raw and Engineering Unit

values for AI channels as shown below.

52




Poll Holding Register: 97-100(Analog Input Channels Type)

Default type is voltage for 3 analog channels and last one is battery.

Note 1: Type: 0- Inactive, 1-Current, 2-Voltage, 3-Battery, 4-Temp, 5-Humidity,6- RSSI.

Step 3: Enter values as you need for each type of channel. You can use multiple register

writing.

Step 4: Click on the Send button to write it into the i-Sens controller.

When i-Sens wakes up the next time, you can see the changes in the same Holding

Registers: 97 -100 (Un-signed Integer).

Step 5: Give Inputs on channels .

Poll Input Registers: 40 -43 (Raw count for 3 input channels and battery channel) with

i-Sens ID=245 and it will show you the values.

Note 2: Data type of these registers must be Un-signed Integer.

Step 6: Poll Input Registers: 52 -59 (EU for 3 input channels and battery channel) with

i-Sens ID=245 and it will show you the values.

Note 3: Data type of these registers must be Float Inverse.


i-Sens Slave ID.

53

Configure i-Sens AI Channels for Raw values Calibration

Calibration is required only when the AI input is not in range of 1-5V/4-20mA.

A. Through ICONFIG

Step 1: In ICONFIG, open the project and Click on the i-Sens . It will show you the Properties

window. Click on the Advanced Tab.

Step 2: Select Channel Calibration and under Calibration Type slide onto Raw.

Step 3: Select Channel 1 and you will see four parameters. These parameters are available for all

3 Analog Channels and also for the Battery channel.

Step 4: Select the parameters you want to change and enter the values:

1) Smoothing Factor = 0

2) Resis Value = 2.604

Note 1: For precise results, Resis value=(250 ohms/ Measured resistance between AI +ve and

AI -ve )

3) Calib Low Count = 12840

4) Calib High Count = 64000

54



Step 6. To upload the configuration Right click on i-Sens and select upload


Step 7. Select the tabs values you want to upload. You can choose what tabs to configure

and upload.

Step 8. Once selected, all or partial, press OK to upload the configuration.

Step 9: Give Inputs to the Analog Channels from source (Voltage/Current) through the

corresponding pins.

Note 2: Source +ve to AI+ of Channels.

Source –ve to AI- of Channels.

Note 3: Depending on the Input type (Voltage/Current),keep the position of the switches of

PSW2 block.

55

Step 10: After uploading configuration, set the RS-232 Communication with iRecv :

1) Turn the 1st switch of the PSW1 block on i-Sens to “Open” position and

complete the settings for communication with iRecv.


port iRecv

(TX2+,RX2-,G).“Close” pins 1-2&3-4 of JP8&JP9 using jumpers as shown

before.



Step 11: If you want to check on ICONFIG, double click on iRecv and i-Sens tags

to see the changes.

Step 12: It will be shown as tabs in the ICONFIG main window. Connect using the

green button, as shown before. You can see the results as in below figure.

Note 5: Calib Low and High Count varies for each channel.

Channel 2:

Calib Low Count= 12840

Calib High Count= 64000

Channel 3:

Calib Low Count= 13280


Channel 4(Battery):

Resis Value = 1

Calib Low Count = 13280


You can configure the 3 Analog Channels and the Battery Channel with specified Calibration

values through steps 3 -10.

56




Poll Holding Register: 145(Calibration Type)

Note 1: Type: 0- Raw Count,1- Current,2- Voltage.

Poll Holding Registers: 146 -149(Float Inverse) for Channel 1.

Step 3: Enter Raw Low=12840 in Register: 146 -147 and Raw High=64000 in

Register: 148 -149. You can use multiple register writing.


When i-Sens wakes up the next time, Analog channel 1 would have calibrated.

Step 5: Give Inputs on channels.

Poll Input Registers: 40 -43 (for 3 input channels and battery channel) with i-Sens

ID=245 and it will show you the Raw data on channels.

57


Step 6: You can write Raw Min and Raw Max into

Holding Registers: 150 -153 for Channel 2

Holding Registers: 154 -157 for Channel 3

Holding Registers: 158 -161 for Channel 4 (battery) and you can see the Raw

data on these channel registers.


When i-Sens Communicates with iRecv using Radios ,you can still poll the above registers


58

Configure i-Sens AI Channels for Engineering Unit(EU)values Calibration

A. Through ICONFIG

Step 1: In ICONFIG, open the project and click on the i-Sens . It will show you the

Properties window. Click on the Advanced Tab.

Step 2: Select Engineering Units.

Step 3: Select Channel 1 and you will see two parameters. These parameters are available

for all 3 Analog Channels and also for Battery channel.

Step 4: Enter the values for:

Engineering Min= 0

Engineering Max=1500






and upload.


Step 9: Give Inputs to the Analog Channels from source (Voltage/Current) through the

corresponding pins as shown in the previous diagram.

Note 1: Source +ve to AI+ of Channels.

Source –ve to AI- of Channels.

Note 2: Depending on the Input type(Voltage/Current),keep the position of the switches of PSW2

block.

59


iRecv :


do the settings for communication with iRecv.


port of

iRecv(TX2+,RX2-,G).“Close” pins 1-2&3-4 of JP8&JP9 using jumpers as

shown before.



Step 11: If you want to check on ICONFIG, double click on iRecv and i-Sens tags again

to see the changes.


button, as shown before.

Note 4: Calib Low and High Count varies for each channel. EU Low and

high Count depends on the sensor capacity.

60

Channel 2 and Channel 3:

Engineering Min=0

Engineering Max=1500

Channel 4(Battery):

Engineering Min=0

Engineering Max=20

You can configure the 3 Analog Channels and the Battery Channel with specified Calibration

values through steps 3 -10. You can also configure them together and then upload it to i-Sens at

once.




Poll Holding Registers: 31 -34(EU for Channel 1).


Step 3: Enter EU Low=0 in Register: 31-32 and EU Max=1500 in Register: 33 -34.

You can use multiple register writing.


When i-Sens wakes up the next time, Analog channel 1 would have calibrated.


61

Poll Input Registers: 52 -59 (for 3 input channels and battery channel) and it will show

you the EU data on channels.


Step 6: You can write EU Min and EU Max into

Holding Registers: 41-44 for Channel 2

Holding Registers: 51-54 for Channel 3

Holding Registers: 61-64 for Channel 4(battery) and you can see the EU data on

channel registers.

When i-Sens Communicates with iRecv using Radios, you can still poll the above registers


Configure i-Sens AI Channels for Voltage Input-Output Calibration

A. Through ICONFIG

Step 1: In ICONFIG, open the project and Click on the i-Sens . It will show you the

Properties window.

Step 2: Click on the Advanced Tab. Select Channel Calibration and select Raw.

Note 1: Never change the calibration type to voltage/current.

62

Step 3: You can repeat the steps 3-8 for configuring AI channels for Raw/EU as per your

need or both.

Step 4: After uploading configuration, do the settings for RS-232 Communication with

iRecv :

1) Turn the 1st switch of the PSW1 block on i-Sens to “Open” position and set

communication with iRecv.


port of iRecv

(TX2+,RX2-,G).“Close” pins 1-2&3-4 of JP8&JP9 using jumpers as shown

before.



Step 5: Before giving the inputs in the AI Channels, make sure that the switches of the

PSW2 block on i-Sens are pushed towards an “open” position. It is for Voltage

Input-Output.


to see the changes.


button, as shown before. You can also see the AI Channel values as shown

previously.




63

Poll Holding Registers: 97-100 (Un-signed Integer) for all AI Channels. Default value is

Voltage for all 3 AIs.

Poll Holding Register: 145 (Calibration Type). Enter 2 for voltage.

Note 1: Type: 0- Raw Count,1- Current,2- Voltage.

Step 3: Enter the values for all channels. You can use multiple register writing.

Note 2: Type:0- Inactive,1- Current,2- Voltage, 3- Battery,4-

Temperature,5- Humidity.

Step 4: Click on the Send button to write it into the i-Sens controller. Give Voltage Inputs

on AI Channels.

When i-Sens wake up the next time, you can see the changes in the same Holding

Registers: 97 -100 (Un-signed Integer) for all AI Channels.


Poll Input Registers: 40 -43 (Raw data) or Input Registers: 52 -59 (EU data)

for the corresponding input values.

When i-Sens Communicates with iRecv using Radios, you can still poll the above

registers with i-Sens Slave ID

.

64

Configure i-Sens AI Channels for Current Input-Output Calibration

A. Through ICONFIG


Properties window.

Step 2: Click on the Advanced Tab. Select Channel Calibration and select Raw.

Step 3: You can repeat steps 3-8 for configuring AI channels for Raw/EU per your need

or both.


iRecv:




port of


shown before.


65


Note 2: For Current Input-Output, make sure that Resis Value= 2.604 (For precise results, calculate

Resis value). For all 3 Analog Channels and for Battery it should be 1.0.

Step 5: Before giving the inputs in AI Channels, make sure that switches of PSW2 block

on i-Sens is not pushed towards “open” position. It is for Current Input-Output.


to see the changes.


button, as shown before. You can see the AI channel values as shown previously.




Poll Holding Registers: 97-100 (Un-signed Integer) for all AI Channels.

Default value is Voltage for all 3 AIs.

Note 1: Type:0- Inactive,1- Current,2- Voltage,

3- Battery,4-Temperature,5- Humidity,6-RSSI.

Poll Holding Register: 145 (Calibration Type). Enter 1 for current.

66

Note2: Type: 0- Raw Count,1- Current,2- Voltage.

Step 3: Enter the values for all channels. You can use multiple register writing.

Step 4: Click on the Send button to write it into the i-Sens controller. Give the Current

Inputs on AI Channels.

When i-Sens wakes up next time, you can see the changes in the same Holding

Registers: 97-100(for all AI Channels)

Note 3: The Data type of these registers must be an Un-signed Integer.

Step 5: Give inputs on channels.

Poll Input Registers: 40-43 (Raw data) or Input Registers: 52 -59 (EU data) for

the corresponding input values.


registers with i-Sens Slave ID.

67

Configure i-Sens Digital Input Channels

A. Through ICONFIG


Properties window. Click on Basic Tab.

Step 2: Select Digital Input Channels and select Channel 1.

Step 3: Slide onto Digital from list and select it. You can do the same for Channel 2 also.



Step 5: To upload the configuration Right click on i-Sens and select upload



and upload.


68


iRecv :

1) Turn 1st switch of the PSW1 block on i-Sens to “Open” position and do

the settings for communication with iRecv.


port of iRecv

(TX2+,RX2-,G).“Close” pins 1-2&3-4 of JP8&JP9 using jumpers as

shown before.



Step 9: Give Inputs on Digital Input Channels.

Note 2: Source +ve to DI+ve of Channels.

Source –ve to DI-ve of Channels.

Step 10: If you want to check on ICONFIG, double click on iRecv and i-Sens tags again to see

the changes.

Step 11: It will be shown as tabs in the ICONFIG main window. Connect using the green button,

as shown before.



69


Poll Holding Registers : 101-102(Un-signed Integer) for both DI Channels.

Default value is Inactive for both DI’s.

Note 1: Type: 0- Digital,1- Pulse Counter,2- Pulse Accumulation,3-

Inactive.

Step 3: Enter the values for both channels. You can use multiple register writing.

Step 4: Click on Send button to write it into the i-Sens controller.

When i-Sens wakes up next time, you can see the changes in the same Holding

Registers: 101 -102(for both DI Channels)


Step 5: Give Inputs on DI Channels.

Poll Input Status:1-2 (Un-signed Integer) with i-Sens ID=245 for the

corresponding input values.

Note 3: For Low input, the status will be 0.

For High input, the status will be 1.


i-Sens Slave ID.

Configure i-Sens Digital Output Channels

Digital Output Channels can be used for “Well Shut In” function.

70

A. Through ICONFIG


Properties window. Click on Advanced Tab.

Step 2: Select Well Shut In and enter the parameters (as per your need) for:

1) Num. Missed Ack Message = 5 (the No. of failed attempts i-Sens makes to

communicate with iRecv)

2) Digital Output Channel= 1(DO Channel which is used to Shut In the Well

head, when there is a communication problem).

Note 1: Choose any of the Digital Output channel for this. This will create a digital HIGH signal (just for a

second)which will close the well head when there is any improper communication between i-Sens and

iRecv.

You can extend the Digital Output status by changing the Digital Out Setting time of i-Sens.

Holding Register: 14 in milliseconds.

Default is 500 milliseconds.

71

Step 3: In ICONFIG, open the project and click on the i-Sens. It will show you the

Properties window. Click on Basic Tab.

Step 4: Select Time Setting and slide onto Digital Out Setting Time. Select it and enter

the time in milliseconds.

Step 5: Save and upload the settings to i-Sens . Before upload the settings keep the i-





and upload.


Step 9: After uploading configuration do settings for RS-232 Communication with iRecv:

1) Turn 1st switch of the PSW1 block on i-Sens to “Open” position and do

the settings for communication with iRecv.


port of


shown before.



Manual control of “Well Shut In” without waiting for the Missed Ack number.

1) Right Click on i-Sens and slide onto Set Points. Select Digital Out.

2) Select Digital Out-1 and Turn it ON.

3) Click OK and it will be written to i-Sens controller as a message sent

by the iRecv, when the i-Sens wakes up next time.

Note 3: Only Digital Output functionality can be written to i-Sens controller without putting it into

configuration mode.

72




Poll Holding Registers: 130 (Number of Missed Acknowledge Message)

Poll Holding Register: 131 (Digital Output Channel for Well Shut In).

Note 1: Data type of these registers must be Unsigned Integer.

Step 3: Enter the values for both channels. You can use multiple register writing.

Step 4: Click on the Send button to write it into the i-Sens’s controller.

When i-Sens wakes up next time, you will see the changes

Holding Registers: 130 -131

73

Step 5: Poll Coil Status: 1-2 (Un-signed Integer) and when there is a missed

communication Coil Status 2 will give a HIGH signal.

You can extend the DO status by writing specified time written in milliseconds

on Holding Register: 14(Un-signed Integer)



Configure i-Sens Analog Input Channels for Report By Exception(Alarms)

The Report By Exception is similar to the Alarms feature. This does not set any Flags on i-Sens but

sets Status flags on iRecv for changes in input values. If it is activated for any Channel, i-Sens

sends messages to iRecv when there is any change in Analog input values.

A. Through ICONFIG


Properties window. Click on the Alarms Tab.

74

Step 2: Select AI Channel Alarms. Click on Channel 1.

Step 3: Enter the values as you need for parameters:

1) Raw Count Min= 11500

2) Raw Count Max= 55000

3) Percentage Change= 2

Step 4: Save and upload the settings to i-Sens. Before uploading the settings keep the i-





and upload.


Step 8: After uploading configuration do settings for RS-232 Communication with

iRecv :

75




port of iRecv


shown before.



Step 9: Give Inputs on Analog Input Channels of i-Sens.

Note 2: Source +ve to AI +ve of Channels.

Source –ve to AI -ve of Channels.

Step 10: Connect to iRecv in ICONFIG. In iRecv communication window click on the

Network Alarms Tab and there you can find if any Channel Alarm is ON or not

and which i-Sens created it.

Step 11: To clear the Alarms, Right Click on iRecv and select Set Points. Slide onto

Clear Alarms. Once you clear the alarm, Channel Alarm will show OFF until

there is any Report by Exception/Alarms.




Poll Holding Registers: 65 (AI channel 1 Alarm Raw Count Min value) Default is 0- no alarm.

Poll Holding Register: 66 (AI channel 1 Alarm Raw Count Max value) Default is 0 - no alarm.

Poll Holding Register: 67 (AI channel 1 Alarm Percentage Change) Default is 0 - no alarm.

Note 1: Data type of these registers must be Unsigned Integer.


Step 4: Give Inputs on analog channels of i-Sens.When i-Sens wakes up next time, you

can see the changes. You can do the same for all AI channels.

Note 2: Holding Register: 69 -71 (For Channel 2 Alarms)

76

Holding Register: 73 -75 (For Channel 3 Alarms)

Holding Register: 77 -79 (For Channel 4-battery Alarms)

Step 5: Poll Input Status: 86 -100 with iRecv ID=1(Active Alarm Indicator for VRD 1 to 15)

Note 3: i-Sens does not create any Alarm status flags on itself but it creates the analog status flags on

iRecv. The status flag will be 1 when there is a change and it will be retained unless it is being Cleared or

there is an appropriate change in analog values.

Step 6: To clear Alarms, Poll Coil Status:12 with iRecv ID=1. Click ON and it will reset

all alarms to zero upon the next transmitting wake up time. When i-Sens Communicates with

iRecv using Radios, you can still poll the above registers with i-Sens Slave ID.

77

Configure i-Sens Digital Input Channels for Report By Exception(Alarms)

A. Through ICONFIG


Properties window. Click on Alarms Tab.

Step 2: Select DI Channel Alarms. Select :

1) Sample Alarm = ON

2) Alarm Value for DI 1= ON

3) Alarm Value for DI 2= ON

You can select any DI channel or both at the same time.

Step 3: Save and upload the settings to i-Sens. Before upload the settings, keep the i-Sens

in Configuration Mode.



78


and upload.



iRecv:




port of iRecv


shown before.


(Turn ON i-Sens after iRecv)

Note 1: It is better to Turn ON i-Sens after iRecv for better registration of i-Sens

on iRecv.

Step 8: Give Inputs on Digital Channels of i-Sens.

Note 2: Source +ve to DI+ve of Channels.

Source –ve to DI-ve of Channels.

79

Step 9: Connect to iRecv in ICONFIG. In iRecv communication window, click on

Network Alarms Tab and there you will find if any Channel Alarm is ON or

not and which i-Sens created it.

Step 10: To clear the Alarms, Right Click on iRecv and select Set Points. Slide onto

Clear Alarms.

Once you clear the alarm, Channel Alarm will show OFF until there is any

Report by Exception/Alarms.

Note 3: Since Digital Input works like a status, sometimes it does not create any status

flags on iRecv for its value change

.




Poll Coil Status: 32= ON(Turn on Sample Alarm for Digital Inputs).

Poll Coil Status:19= ON (Send Alarm Data-default is ON)

Poll Coil Status:65= ON(Alarm Value for DI 1)

Poll Coil Status: 66= ON(Alarm Value for DI 2)

Step 3: Click on the Send button each time to write it into the i-Sens controller.

When i-Sens wakes up next time, you will see the changes.

Step 4: Give Inputs on digital channels of i-Sens.

Poll Input status:86-100 with iRecv ID=1 (Active Alarm Indicator for VRD 1 to 15)

Note 1: i-Sens does not create any Alarm status flags on itself, but it creates the digital

status flags on iRecv. The status flag will be 1 until there is an appropriate change. The

status flag will be 1 when there is a change and it will be retained unless it is being

cleared or there is an appropriate change in digital values.

80

Step 5: To clear Alarms, poll Coil Status:12 with iRecv ID=1 and Turn ON the register.

It will reset all alarms to zero upon the next transmitting wake up time.



81

Jumper Settings for iSens Rev 0.0

Jumper

Number

Setting Description

JP1 Main power connector (3.5V to 15V)

JP2 I2C connector

JP3 Tank Monitor connector

JP4 Analog Out connector

JP5 Analog In 1 (A1) connector



JP8 Digital Ins connector

JP9 Digital Out connector

JP10 RS232 Connector

PSW1 1 (OFF)

2 (ON)

3 (OFF)

4 (OFF)

Set to ON to go to configuration

Set to ON to power LED

Set to ON to power the DAC circuit

Set to ON to bypass the reverse protection diode

PSW2 1

OFF

ON

Read current (0-23.1mA) for A1

Read voltage (0-5.12) for A1

PSW2 2

OFF

ON

Read current (0-23.1mA) for A2

Read voltage (0-5.12) for A2

PSW2 3

OFF ON

Read current (0-22.6mA) for A3 Read voltage (0-5.00) for A3

SW1 Power switch or jumper to enable power to board

SW2 Switch or jumper to select 10V or 15V for sensors

SW3 Download switch

SW4 Force Transmit switch and hardware trigger (INT0)

82

Voltage Sensor Mode

iSens can be configured to process analog data in the ranges described in the section

“iSens Sensor Connection.” Analog signals can be connected either as single ended or

differential. The only real distinction is in how the external wiring is done.

Differential connection tends to be more immune to common mode and ground loop

problems. Regardless, the digital output provided by iSens to the Gateway is 0 - 65535

in decimal linearly, with 65535 representing channel full scale. Inputs are sampled by

the microprocessor in a 20-microsecond window at intervals equal to the supervisory

rate.

When sensors are powered by the internal circuitry, power is applied to the sensor and

held for user selectable times, in 20 millisecond increments from 20 milliseconds to 3

seconds, prior to sampling. This is to allow the sensor electronics to stabilize prior to

sampling. This is also called Sensor Wake-up time, which can be configured through

firmware.

For low power sensors (5-12 VDC @ 3-5 mA), this has a small but finite effect on battery

life, so the shortest "settling time" and lowest applied voltage that is useful should be

used. Note that each sensor channel cannot have different operating voltages applied.

The voltage selected will be common to all channels.

Input voltage = count * 5 / 65535

Current Loop Sensor Mode

This mode is identical to the Voltage Sensor Mode except that the input voltage is

developed by the loop current drop across a high accuracy shunt resistor. When

programmed to the Current Sensor Mode, the required resistor value is 250 Ohms. This

enables an input current range of 0 – 22.5 mA . This resistor is implemented in iSens

by switching corresponding SW on circuit board as per the table above.

4-20 mA loop powered devices are powered from the iSens by the same method

described above for voltage sensors using the same rule of lowest voltage and shortest

settling time. This is particularly important for current loops, as the power used is

significantly higher and can dramatically affect battery life. See “Using iSens to Power 4-

20mA Loop Systems” for a further discussion of 4-20 mA iSens powered sensors. The

input current reads up to 22.5 mA.

Input current = (count * 5 / 65535) / 222.1432

83

Configuring the iSens to support 4-20mA sensors

This chapter describes the precautions that must be taken when using the iSens to

power 4-20mA loops.

Not all 4-20 mA loop powered transducers are alike. Some precautions must be taken

before using the ISENS to power 4-20 mA loops. The maximum voltage available from

iSens for loop power is 15 VDC. All 4-20 mA sensors have a stated "operating area,"

which is related to input voltage and loop resistance. The loop resistance is the sum of

line (wire) resistance and the shunt resistance used to measure current. For the

internal iSens shunt, the resistance is 50 Ohms, depending on the jumper settings.

Most manufacturers state operating areas with a simple formula, such as:

� Required supply voltage = 10V + (.02 * Loop Resistance)

If, in this particular case, the connecting wires have a resistance of 3 Ohms and the

internal shunt is 50 Ohms, the required voltage is:

� 10 + (.02 *(50 + 3)), or 11.06 volts

iSens can supply this sensor with 12 Volts of power.

Some of the newer, multifunctional, digital sensors that provide 4-20 mA as a

secondary output path are designed for standard 24 VDC SCADA supplies. These will

generally work in the 4-20 mA mode with lower loop voltage, but tend to have operating

areas bounded at the low end by 12 Volts into 0 Ohms. These will probably work with

12-15 Volts, but test first!

One other caution concerning digital, multivariable sensors is that they usually require

1 to 2 seconds after application of power to stabilize and produce accurate readings.

This long operating period produces a serious current drain and can greatly reduce

battery life. In the extreme case, it can cause voltage sag from the iSens, resulting in

serious accuracy degradation.

All 4-20 mA sensors require some finite "settling" time TO GIVE A GOOD READING;

however, analog devices tend to require far less time than the newer digital equipment,

averaging 20 milliseconds or less. For any 4-20 mA sensor, this "settling time" should

be verified either by information from the manufacturer or by testing before the device

is used. Devices specifically designed for 24 VDC power cannot be powered by an iSens.

84

4.0 Installing a iSens

Pre-installation

Installation must comply with EN60079-14. Install the i-Trasmit in accordance with the wiring

methods, as specified in Article 501-4(b) in the National Electric Code, NFPA 70.

Prior to field installation, the following actions should be

completed:

• Determine whether internal battery or external power is to be used.

• Based on information from this manual, determine the following transmitter

parameters required for your particular implementation:

a. Type of input (0 – 20 mA based on switch settings, 0 – 5 V, status, RTD, etc.) for each channel

b. Transmitter identification codes, such as transmitter ID

c. Wakeup interval (time for power saving mode)

d. DC power to sensors 10 V or 15 V

e. Sensor settling time

ACCORDINGLY, THE ISENS FIRMWARE NEEDS TO BE CONFIGURED AND THE JUMPERS/SWITCHES ON THE BOARD MUST BE SET.

85

Enclosure Mounting Configuration

Prior to mounting, ensure that the SW1 switch on the iSens is securely in the OFF

position.

WARNING: EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS 1, DIVISION 2.

The iSens is a non-incendiary device enclosed in a NEMA 4X rated class 1 div 2 rating.

To function as a non-incendiary device, the iSens must be connected only to non-

incendiary external sensing devices using the conduit entry points into the lower

housing wall. This equipment is NOT field repairable.

� Install the iSens enclosure at a conveniently accessible location.

� Install the iSens enclosure near the sensor or group of sensors to be sampled. Keep

the sensor cable length optimal to avoid power loss.

� Install the iSens enclosure using the housing base mounting ears if to be mounted on a wall. The iSens in an explosion-proof housing can be mounted on process

piping when integrated with sensors.

� Install and contain the wire harness from the sensors to the iSens transmitter via location approved applicable conduit/outdoor cables. Install in accordance with wiring methods as specified in Article 501-4(b) in the National Electric Code, NFPA

70.

86

CONNECTING THE ISENS BOARD TO THE POWER SOURCE

Battery Power Operation

Caution! Observe battery polarity while connecting battery pack.

WARNING: EXPLOSION-HAZARD - DO NOT REPLACE BATTERIES UNLESS POWER HAS BEEN SWITCHED OFF AND THE AREA IS KNOWN TO BE NON-HAZARDOUS.

• Connect the harness of the battery pack to the battery power terminal connector on

the main board ensuring the proper polarity of battery power to the board.

DC Line Power Operation

Caution! Observe DC polarity while connecting external power supply

87

WARNING: EXPLOSION-HAZARD - USE UL/CE APPROVED CLASS 2 POWER SUPPLY AS EXTERNAL POWER SOURCE.

Pull the user's external 6 to 16 volt DC wires through one of the conduit entry points in

the lower housing wall. Connect the appropriate stripped and tinned wire ends of the

external DC line power to DC supply terminals.

Connecting Sensors

Ensure that all wiring enters the iSens enclosure through weatherproof conduit and/or

conduit fittings, as per the appropriate following sections of the National Electric Code.

Area National Electric Code reference

Cl. 1 Div 1 Area Refer to section 501.4.A of NEC Code Cl. 1 Div 2 Area Refer to section 501.4.B of NEC Code Cl. 2 Div 1 Area Refer to section 502.4.A of NEC Code Cl. 2 Div 2Area Refer to section 502.4.B of NEC Code Cl. 3 Refer to section 503.3 of NEC Code Intrinsic Safe Systems Refer to section 504 of NEC Code

Cl. 1 Zone 0, 1 & 2 Refer to section 505.15 of NEC Code (Applicable only when specified by the end user.)

WARNING: EXPLOSION-HAZARD - DO NOT MAKE OR BREAK CIRCUIT CONNECTIONS WHILE POWER IS ON UNLESS AREA IS KNOWN TO BE NON-HAZARDOUS.

The iSens sensor interface board is capable of supporting 3 analogs, two digital sensors

and one hardware interrupt device. For each sensor, locate and connect the stripped

and tinned wire ends of the external sensor DC power and return lines to the V and G

screw terminals on the terminal block for each channel.

Locate and connect the stripped and tinned wire ends of the external sensor output

signal and return to the screw terminals A and G.

If the sensor output signal is a current loop, locate the 50/249 Ohm resistor enable

jumper (JP1, JP2, JP3, JP4, JP5 and JP6) on the iSens main board next to the

appropriate sensor I/O terminal block. For 0 – 22.5 mA, the jumper is selected. There

is a 249 Ohm resistor on-board that gets enabled in the circuit for current loop.

88

Notice: Any grounding or common connection of sensor cable shields shall be done on the conduit box nipple. No power, safety, or earth ground connections are to be made to the circuit board, circuit board mounting bracket or terminals.

iSens Board

Each I/O Point signal input will be independently configurable into one of two modes as listed

below:

I/O Point Mode Sensor I/O Description

A Single Ended Voltage Sensor (0 – 5 VDC) B Single Ended Current Sensor (0 – 22.5 mA)

89

Mode A - I/O Point Single Ended Voltage Sensor

In Single Ended Voltage Sensor Mode, the I/O Point may optionally provide power to the sensor and will

be programmable during setup to accept a voltage in the 0 – 5V DC input range.

For full accuracy, the loop resistance to the sensor should be less than 100 Ohms. In this mode, the I/O

Point, depending on power source, will be wired as shown in the following figures:

iSens Mode A with iSens Module Supplied Power

iSens Mode A with External Power

Mode B - I/O Point Single Ended Current Loop

In Single Ended Current Loop Sensor Mode, the I/O Point may optionally provide power to the sensor

and will detect currents in the range from 0 to 22.5 mA. For full accuracy, the loop leakage current

should be less than 5µA.

The internal precision 249 Ohm resistor must be selected with the corrosion resistant hardware jumper

supplied and located just below the channel input terminal block. Wiring is as shown in the following

figures.

90

iSens Mode B with iSens Module Supplied Power

When powering more than two 4-20 mA current loop sensors, a special high current battery pack should be used in place of, or with, the standard battery pack.

iSens Mode B with External Power

91

Monitoring a Project

The i-Config user Interface provides the user access to basic data monitoring and network diagnostics.

Once an iSens is created and all devices are configured, the system can be tested by connecting the i-

Recv to a PC running i-Config.

If you select a specific i-Recv in the Network, and double click the icon in the Project Explorer Pane, a

tabular report will appear in the middle of the application screen displaying the i-Recv name and

showing basic data for all associated iSens.

This screen will show basic diagnostics data for each associated iSens.

This report will also have several tabs with each tab providing a significant amount of data about the

network operating state and diagnostics data for proper troubleshooting of the system.

92

4.1 i-Recv Diagnostics Report

4.1.1 Network Info Tab

The Network Info Tab provides data about all associated iSens including registration status,

Operating Mode, and iSens status.

4.12 Triggered Calculations Tab

The Triggered calculations tab provides data about the calculations or any mathematical

operation the iSens are executing. This would include calculating Engineering units, Square

Roots or linear accumulation or alarms.

4.1.3 Network Alarms Tab

The Network Alarms tab provides data about the alarms triggered by any of the associated

iSens. Any alarm that is triggered on a specific iSens based on Min, Max or percent change will

be reflected in this screen.

4.1.4 WMP Msg Status

The Wireless Message Protocol WMP Msg Status tab provides data about the communications

status between all associated iSens and the i-Recv. This includes data such as Time Since Last

Message, time stamp of last message, time till next message (calculated based on iSens

configuration) and a number of messages received from each iSens.

4.1.5 Network RF Status

The Network RF Status tab provides data about the RF signal status between the iSens and the i-

Recv and provides data about bad messages received from each associated iSens.

4.1.6 Debug

The Debug tab provides a powerful tool to log data and message format to allow an advanced

user to decode messages and detect the source of errors if they are occurring.

93

iSens Diagnostics Report i-Report and i-Chart

For monitoring any associated iSens, double click the particular iSens, and another tabular report will

appear showing all data and I/O channels from that particular iSens.

The report will have two separate tabs, i-Report and i-Chart

4.2.1 i-Report

i-Report provides the user a snapshot of the selected iSens will all I/O analog and digital current

reading. The i-Report will display all Analog values in both Raw digital count or engineering value

if the engineering value calculation is triggered.

94

4.2.2 i-Chart

i-Chart will provide the user a time based trend starting at time 0. This refers to the time a user

selects an iSens report and presses the green Start Button. The i-Chart can be configured for

Zooming in or out, saved and printed. All values, colors, and scales can be changed and adjusted

to fit the user preferences.

95

Maintenance

This chapter provides instructions for maintaining iSens transmitters. This chapter also

contains a troubleshooting guide for diagnosing possible problems with the transmitter

unit.

Warning: Explosion Hazard - Always turn the ON-OFF switch to the OFF position and disconnect the power source prior to any maintenance work. Keep lid tight and do not open when an explosive gas may be present.

iSens transmitters are designed for minimal maintenance and no field repairs.

Changing the batteries is the only scheduled maintenance activity. The batteries for the

ISENS transmitter are rated for 1 to 5 years of life based on the sampling time, number

of sensors, and whether or not the sensors are loop powered. Typically, if the sensors

are externally powered, you can use the batteries for maximum life. In such case, a

Class II power supply is required for instrument loop power.

Warning: Explosion Hazard - When in hazardous locations, decommission the unit and service it in a gas-free environment outside classified area.

The latest version of i-Sens transmitters internally sense the battery power and send

this data to the receiver as part of the data packet using the serial interface to the

receiver. A remote operator receives a 20-30 day notice to schedule maintenance activity

before the batteries are completely drained.

The only maintenance tools that a technician needs for maintenance of

iSens transmitters are a medium sized screwdriver, terminal sized screwdriver and a

multimeter.

Warning: Always clean the equipment with a dampened cloth rather than a dry piece of cloth.

96

Troubleshooting Guide

The following is a comprehensive troubleshooting guide written for easy maintenance of

the transmitter unit:

1. RED LED is not ON.

� Cause: Power issues. Most likely the transmitter is not getting enough power to boot up.

� Action: Open up the iSens transmitter enclosure and check the power supply. Check if the voltage across the battery leads or the power connector is greater than 6.0 V.

If the iSens is battery powered, check if the battery is dead or on low-voltage. If the

iSens is externally powered, check the power supply wiring.

If the problem persists, decommission the unit and send back to vMonitor for repairs.

2. The Transmitter is not powering the sensor. There are no readings displayed on the Sensor LCD screen.

� Cause: Most likely the transmitter does not have enough power to power the

sensors or the unit has insufficient sensor settling/wakeup time.

� Action: iSens is designed for power-save mode. During this mode, there is no power to sensors. When the iSens comes out of sleep mode for Acquisition/Transmit mode, you can measure voltage at V and G terminals. This is when the iSens loop

powers the sensors, gets the reading, and transmits over radio link.

If you see power on V and G terminals, verify the sensor settling time with the

Manufacturer. Crosscheck the settling time in iSens firmware.

3. The operation of the unit looks fine with alternate power save mode and transmit modes, but there is no data at the Gateway.

� Cause 1: Radio module is not placed securely and firmly.

� Action 1: Verify the installation of the radio module.

� Cause 2: Incorrect Jumper settings.

� Action 2: Verify the settings for JP1, JP2, JP3, JP4, JP5 and JP6.

� Cause 3: Radio communication issues, such as antenna misalignment, external interference, bad signal, high noise in signal, faded signal, bad antenna cable, bad antenna connectors, loose jumper cable connections, lightning strike, bad

transmitter, incorrect polling of TX ID or Modbus registers.

� Action 3: Consider all of the above cases and rule out the possibilities one-by-one.

Repeat the same checks for the master station.

97

New Firmware, i-Recv

The i-Recv will have the latest firmware version loaded, however if a new firmware is required,

the following procedure will allow a user to download a new firmware into the i-Recv.

The following tools are needed to upload the new firmware.

Computer with a serial port

HyperTerminal with i-Config application

• Setup Hyper Terminal for 9600, 8 N &1 for the corresponding serial port.

• Power off the i-Recv.

• Press and hold Switch 4 (SW4).

• While holding SW4 power the i-Recv, a smile face must show in Hyper-terminal.

• The i-Recv program is interrupted now and is ready to receive the new code.

• Disconnect or close Hyperterminal.

• Open i-Config application.

• Click on Upload Hex File on the icon bar as shown below

• A window will pop up to choose the Hex file to download.

• Once selected, choose open, the firmware download will initiate.

• Once completed the process is ready and the i-Recv now has a new firmware. It is also

back to default configuration.

98

Checklist

Mount iSens Remote Device with antenna straight up

Attach conduit and sensors as required & feed wire through to wiring compartment

Complete sensor wiring

Set dip switches, selecting between voltage or current input

Make power connection

Close the iSens Remote Device

Mount i-Recv

Mount Antenna, straight up, attach antenna to i-Recv

Load the i-Config User Interface software into PC

Attach PC to i-Recv

Attach and apply power to i-Recv

Start i-Config User Interface software

Observe the set up page

Name each iSens Remote Device and indicate any iSens which would be supported by another i-Recv

and ignored by this i-Recv

Indicate the order in which the iSens are to be displayed

Set the sampling interval for each iSens

Set the transmission interval for each iSens

Label each sensor on each iSens Remote Device

Indicate the unit label for each sensor: mA or V

Indicate whether each sensor is an interrupting sensor, or purely a sampling sensor

For each analog interrupting sensor, determine the change which would trigger an interrupt

For each digital sensor determine whether the indication is normally on or normally off

99

Map the data from each sensor to a Modbus register

Map the data from selected Modbus registers to the discrete outputs

Attach discrete outputs to a local Flow Computer, RTU or PLC

Attach Modbus cable to local Flow Computer, RTU or PLC

Switch to the data monitoring page and observe the collected data

Backup Mode: Configures the device to operate as a backup. A gateway that is configured to be a

backup receives all messages from the transmitters, but does not respond to them. A backup i-Recv

shares a Slave ID with the active i-Recv and can be switched from backup mode to active in the event

that the active i-Recv fails.

100

Mapping Register

i-Sens Coil

Address Description Default

1-4 Digital Output

5-8 Reserved

9 Reset Board

10 Restore Defaults

11 Restore Factory Defaults

12 Clear Alarms

13 Reserved

14 Reset Received/Sent Message Counts

15-16 Reserved

17 Send Basic Data (Raw Count, EU, Digital Status, Response Time and Message Count) Message Flag (default is on)

TRUE

18 Reserved FALSE

19 Send Alarm Data (default is on) TRUE

20 Send Config Data after sending Register Msg FALSE

21-24 Reserved

25 Shut down modem in sleep mode TRUE

26 Provide Power to Sensor when waking up TRUE

27 Encryption is On (cannot be changed) TRUE

28 Battery Diode Flag (default is on) TRUE

29 Reserved

30 Reserved

31 Use Time Synchronzation for Reporting FALSE

32 Turn on Sample Alarm for Digital Inputs TRUE

33 Register Message Ack Flag (only for i-Sens) TRUE

34 Un-Register Message Ack Flag (only for i-Sens) TRUE

35 Basic Message Ack Flag (only for i-Sens) TRUE

36 Reserved

37 Reserved

38 Send Next Mail Box Message Ack Flag TRUE

39 Reserved

40 Reboot Message Ack Flag (only for i-Sens) TRUE

41 Modbus Read Request Message Ack Flag (only for i-Sens) TRUE

42 Modbus Write Request Message Ack Flag (only for i-Sens) TRUE

43 Modbus Response Message Ack Flag (iRecv Only) TRUE

44-64 Reserved

65 Alarm Value for DI 1 TRUE

66 Alarm Value for DI 2 TRUE

67-100 Reserved

101

i-Sens Status

Address Description

1-4 Digital Input

5-8 Reserved

9-12 Min/Max Alarms for AI channels (1-4) status flags

13-16 Reserved

17-20 Percent Change Alarm for AI channels (1-4) status flags

21-24 Reserved

25-32 Reserved

33-40 Reserved

i-Sens Input

Address Description

1 i-Sens MODBUS Slave ID

2-3 Serial number

4-5 Firmware version number (float)

6 Hardware Type

7 Actual Slave ID (when we are in Configuration Mode Register 1 is changed to ID 100)

8 Actual Operating Mode (when we are in Configuration mode this register reflects the actual mode)

9 Reserved

10 Number of registration attempts

11-20 Reserved

21-22 Board Current Time

23 Time since last received message

24 Message Response Time (time to receive ACK message)

25-26 Number of Messages Sent since start

27-28 Number of messages Received since start

29 Reserved (internal Wake up counter)

30 Reserved (Signal Strength Wake up counter)

31-39 Reserved

40-43 Raw Counts for Analog channel 1-4

44-51 Reserved (internal voltage values)

52-59 Eng Units for AI channels 1-4

60-61 internal Board Temperature

62-65 Last Raw Count value for channel 1-4

66-75 Reserved (internal Msg header)

102

75-78 Reserved (last 3 msg IDs)

79-80 Reserved (Password Timer)

81-180 History data for analog input channels 1-4 (81 msg ID # 1 with 82-85 registers are raw data for msg ID # 1, 86 msg ID # 2, 87-90 raw data for msg ID # 2, etc…)

181 last adjusted sleep time

181 Signal Quality Strength (ZIBGEE Pro Radio is 36-100)

182:183 Last Time Signal Strength was measured

i-Sens Holding

Address Description Default

1 Prmary i-Recv Slave ID To report to 1

2 Secondary i-Recv Slave ID to report to 0

3 Sleep Internal (in seconds) 30

4 Sample Rate in milliseconds (Power Mode Only) 10

5 Pulse Reset Time (in seconds from Midnight) (Power Mode Only) 0

6 Sensor Settling Time (in milliseconds) 50

7 Modem Settling Time (in milliseconds) 50

8 Delay before Shutting the Modem down after sending data (in milliseconds) 10

9 Delay between message transmissions (in milliseconds) 10

10 Delay before Sleeping (in milliseconds) 10

11 Time Zone 0

12 Analog Out Settling Time (setting this will cause the AO to written for this amount of time then reset to 0)

1000

13 Hour Time Offset to sync reporting (-1 is disabled, 1 means that the report interval is adjusted to be offseted by 1 min so if the report interval is 5 min then we will transmit data at 6 min, 11 min, 16 min ,etc)

0

14 Digital Output Setting Time (setting this will cause the DO to be written for this amount of time then reset to 0 after time expires)

500

15 Operation Mode (1-battery, 2-power, 3-modbus) 1

16 COM Baud Rate 9600

17 COM Parity 0

18 COM Stop bits 1

19 COM Data bits 8

20 Differential Channel Type 0

21 Msg Ack time out (in seconds, default is 2) 2

22 Msg Ack Retry Count (default is 1) 1

23 Report Transmit Factor (this is used with register 3 sleep time to determine how often to report to the iRecv. So if this value is set to 10 and register 3 is set to 60 seconds then i-Sens will report every 10 min to the iRecv unless there is an alarm)

10

24 Radio API Mode (0-off, 100-On) 100

25 Raw Min Count for AI Channel # 1 12840

26 Raw Max Count for AI Channel # 1 65535

27 Reserved 0

28 Reserved 0

29 Reserved 0

30 Reserved 0

103

31-32 Engineering Low for AI Channel # 1 0.0

33-34 Engineering Max for AI Channel # 1 1500

35-44 same as registers 25-34 for AI channel # 2 ~


55-64 same as registers 25-34 for AI channel # 4

65 AI channel # 1 Alarm raw count Min value (default is 0 - no alarm)

66 AI channel # 1 Alarm raw count Max value (default is 0 - no alarm)

67 AI channel # 1 Alarm Percent Change (1 represent 1% change, 15 is 15% change, etc) (default is 0 - no alarm)

68 Reserved




81-82 Smoothing Factor for AI channel # 1 0

83-84 Resis Value for AI channel # 1 1




97-100 Analog Input Channels 1-4 Type (0-inactive, 1-current, 2-voltage, 3-battery, 4-Temp, 5-humidity, 5-rssi)

1,1,1,3

101-104 Digital Input channels 1-4 Type (3-inactive, 0-digital, 1-Pulse Counter, 2-Pulse Accumulation)

0,0,3,3

105-108 Analog Output Channels 1-4 Type (0-inactive, 1-current, 2-voltage) 1,1,0,0

109-110 Analog Output Coeff factor 204.918

111-112 Analog Output Constant -0.002

113-114 Analog Output Correction Factor 1.0

115-116 Analog Output Correction 1st Poly Coeff (2nd Poly Eq) 0.0

117-118 Analog Output Correction 2nd Poly Coeff (2nd Poly Eq)

119-122 Analog Output for AO channels 1-4

123 Set new Slave ID 0

124-125 Set Board Time (unix time since 1970) 0

126 Reserved

127 Max time to download Mail Box messages 10

128 Reset Comm Port Idle Time (in seconds - default is 10) 10

129 Max Registration Attempts 10

130-140 Reserved ~

141-142 Password Value

143-144 New Hardware Serial Number

145 Calibration Type (0-Raw Count, 1-Current, 2-Volt) 0

146-147 Low Calib for Channel 1 12840

148-149 High Calib for Channel 1 64000







Documents

ISensIO Manual Rev 1.3