INTELLERGY SENSOR CONTROLLER SETUP
MANUAL
REVISION: 1.3
SENSOR CONTROLLER & EMONITOR GATEWAY
An installation guide for the Intellergy Sensor Controller.
©2013 Intellergy, Inc.
This manual may contain proprietary information about the product described. The manual is for instruction in
setting up and using the Sensor Controller. Any proprietary information illustrated or described in it for the purpose
of helping you set up and use the product remains the protected intellectual property of Intellergy, Inc. This manual
may not be copied, reproduced, or distributed in any way in any form without express written permission of
Intellergy, Inc.
1
Sensor Controller Overview:
The Intellergy Sensor Controller is a microcontroller designed for monitoring and controlling building systems. The
controller features Modbus Rtu communication protocol for connection to a Modbus enabled gateway device. The
sensor controller handles a variety of inputs and outputs for integration with a wide range of sensors. Multiple
Intellergy Sensor Controllers can be placed in series via the Modbus protocol to expand analog and digital
inputs/outputs. One sensor controller has the following inputs an outputs:





4 Analog Inputs
4 Pulse Inputs
4 Digital Inputs
4 Digital Outputs
20 1-Wire ID's (15 Temperature & 5 RH/T ~ Multi)
The following is a guide on how to connect a variety of building monitoring sensors to the Intellergy Sensor
Controller.
Table of Contents:
1.
Sensor Controller Connection
2.
Powering Up & Communication Connection
3.
Embedded Server Connection
4.
Counter Inputs/Connections
5.
Analog Input Connection
6.
Digital Input Connection
7.
Digital Output Connection
8.
1-Wire Connection
9.
Sensor Controller Channel Description/Pinout
2
Sensor Controller Connection:
The Intellergy Sensor Controller is packaged for installation on 35mm Din Rail used in most industrial applications.
Din rail is easily installed in enclosures or mechanical room panels. A gateway device is needed to push data to the
Intellergy cloud servers. If an eMonitor system is going to be installed or already installed the eMonitor Gateway
can serve as a gateway device.
Powering Up & Communication Connection:
The sensor controller is powered though a 6-24 VDC power supply rated at 1 amp. The sensor controller comes
standard with a +12 VDC 12 Watt wall transformer. A din rail mountable universal power supply can be also
supplied which allows for multiple Sensor Controllers to be power by one source where applicable. Figure 1 shows
the communication connection diagram for the Sensor Controller.
Figure 1. Sensor Controller communication connection diagram.
A single sensor controller should be connected via the RS-232 “Serial” port on the gateway device. If using multiple
sensor controllers on one gateway device the RS-485 connection should be used allowing for multiple sensor
controllers to be “daisy chained” together. If Powerwise has provided you with a RS-232 cable the connection
should be made like that shown in Table 1.
Sensor Controller
GND
RX
TX
Cable
Blue –White
Orange
Orange White
Gateway RJ12
GND (6)
TX (5)
RX (4)
Table 1. RS-232 Connection
The following Table 2 shows the connection of RS-485 to the sensor controller when daisy chaining multiple
devices together.
Sensor Controller
GND
A
B
Cable
Blue
Green
Green-White
RS485-RS232 Converter
GND
TX
RX
3
Table 2. RS-485 Connection
In order to get connectivity the gateway device should be powered on before the sensor controller. Once both
devices are powered up a single LED “heartbeat” should be seen on the sensor controller flashing once per second.
Check that both RX and TX lights are flashing once per second to confirm proper RS-232/485 communication. If
only TX is flashing (not communicating) check to make sure the RS-232/485 connection is properly setup.
Embedded Server Connection:
The eMonitor Gateway has an embedded server that can be accessed (when connected to the local network) to help
during setup and commissioning of the product. Data uploaded to the server is averaged over one minute intervals
whereas data seen on the embedded server is updated every 3-5 seconds. Connection to the embedded server is
obtained by connecting to the gateways unique IP address. This can be found on your routers DHCP/connected
devices list. Once the correct address has been obtained enter it in your browser window shown in Figure 3.
IP ADDRESS
SENSOR TAB
Figure 3. Gateway Embedded Server
Some browsers respond better to the embedded server (Chrome, Firefox) than others (Internet Explorer). Once
connection has been made to the embedded server select the Sensors tab to view all sensor data shown in Figure 4.
Figure 4. Gateway Embedded Server with Sensor Controller support.
The sensor controllers will show up under “Remote Sensors” on the embedded server. Each of the sensor controllers
will have a unique id number 1-5 which can be found by counting flashes on power up. All sensor data will be
4
updated every 3-5 seconds on this page, where it will then be averaged for the one minute upload to the Intellergy
servers.
5
Counter Inputs/Connections:
The sensor controller has four counter totalization inputs labeled CT1 –CT4. A variety of sensors can be read using
these four ports with a maximum rated switching frequency of 1 kHz. Common sensors include hall-effect flow
meters, reed switch flow meters, speed sensors, and contact closures. Figure 5 shows the typical setup for the
Omega hall-effect flow meter.
Figure 5. Hall-Effect Flow Meter Connection Diagram
Note: A 10 kΩ pull-up resistor or similar should be placed in parallel with +5 VDC for sink logic sensors (i.e. halleffect sensors). These input channels add the real time pulse count to the existing pulse counts for that channel. This
totalization configuration allows for both total numbers of counts to be recorded as well as the frequency to be
calculated when dividing by the sampling time base. In the case of water flow measurement this means that both
total gallons and flow rate can be calculated for each channel. A scaling factor can be applied on the Intellergy
settings page. Make sure to keep all flow meter information to ensure the correct scaling factor can be applied
during channel setup on the Intellergy website.
6
Analog Input Connection
Analog input signals are connected to channels labeled AN1 – AN4 on the sensor controller. Each channel has an
input range of 0 – 5 VDC with 12 bit resolution. Although the sensor controller records only raw data scaling factors
can be applied on the Intellergy website settings page. Intellergy commonly specifies analog flow meters for
integration into the controller. Figure 6 is the typical connection of the analog flow meter provided.
Figure 6. Analog Flow Meter Connection Diagram
The analog flow meter is powered via a + 5VDC excitation voltage provided on the sensor controller and has two
analog outputs. The first output is a 0.35 - 3.5 VDC analog signal scaled depending on model number to a
proportional flow rate. The second output is an analog temperature reading from 0.35 – 3.5 VDC analog signal
scaled to a proportional temperature flow medium temperature.
Intellergy offers solar radiation sensors used to measure site-specific solar radiation values. These sensors output a
0-5 VDC signal proportional to a calibrated insolation value (W/m2). Figure 7 shows connection of the Pyranometer
provided by Intellergy.
7
Figure 6. Pyranometer Connection Diagram
Other analog sensors such as level sensors, HVAC equipment control set points, etc. integrate in a similar fashion to
the flow meter. An analog input voltage is scaled by an offset and proportional factor to an equivalent measurement.
Scaling factors will be set and saved on the Intellergy settings page of your account.
8
Digital Input Connection:
The four digital input channels are found at connections DI1 – DI4 of the Intellergy Sensor Controller. The digital
inputs should be used to tell whether a sensor is “On” or “OFF” reporting a 1 and 0 respectively. These inputs are
triggered at >3.5 VDC to the “ON” or 1 position. Figure 8 shows a common connection for a current switch or
other digital 2-wire input.
Figure 8. Digital Input Connection Diagram
A current switch senses a specified current flowing thorough an iron ferrite and causes the switch to change logic
from high to low or vice versa depending upon the sensor. In the above case when the rated current trips the
“normally closed” current switch +12 VDC is applied switching the digital input to “ON”.
These inputs will work with a variety of building sensors such as AC switches, DC switches, optical sensors, flame
detectors, etc.
9
Digital Output Connection:
Digital outputs are located on channels labeled DO1 – DO4 on the sensor controller. Each of the four channels can
output 0 or 5 VDC TTL rated to 100 mA maximum output. These channels are designed to offer basic control of
various building systems. Figure 9 shows the basic connection for any digital output sensor or device.
Figure 9. Digital Output Connection Diagram
This connection should only be used to power very low consumption devices and is designed primarily to trigger
relays, HVAC equipment controls, indictors, etc.
10
1-Wire Connection:
These are digital sensors/devices that communicate through the 1-Wire communication protocol. Each individual
sensor is hard coded with a 64 bit unique id that should be pre-labeled for ease of installation by Intellergy. The
Intellergy Sensor Controller is able to handle up to 20 unique devices. Figure 10 below shows typical connection of
1-Wire devices.
Figure 10. 1-Wire Connection Diagram
Intellergy offers a range of custom devices to record building conditions of interest to most building owners.
Temperature sensors come in a small stainless steel barrel and are used to measure ambient temperature, flow media
in pipes, and surface temperatures. Intellergy offers a relative humidity/temperature (RH/T) combined device as well
as a Multisensor, which includes a volatile organic compound (VOC) measurement. The RH/T and Multisensor
require external power supplied by the red (+5VDC) connection shown in Figure 10.
NOTE: For Version 1.00 of the sensor controller the 1-Wire network is not operational. Please attach the 1Wire and Ground pictured above to port D3 (+ & - respectively) on the Gateway.
The 1-Wire network protocol, in which the supplied sensors communicate through, requires a 24 AWG 3-conductor
cable at each sensor location. The network is unique in that it is best setup by attaching all sensors in parallel over
one run of cable throughout the whole sensor network. 1-Wire sensors should be attached in parallel on a single run
of wire when possible. Attachment of the sensor is made easy using 3M Scotchloc connectors with the proper
crimping tool, which can be provided by your Intellergy-Powerwise sales representative. Intellergy 1-Wire devices
require a dedicated power to be supplied, which should be done through the “red” conductor of the twisted three
conductor wire.
11
SENSOR CONTROLLER CHANNEL DESCRIPTION/PINOUT
Connector
Power Input (J1)
Analog Input (J2/J3)
MODBUS RTU (J4/J5)
Pulse Counter Input (J6/J7)
Digital Input (J8/J9)
Digital Output (J10/J11)
1-Wire Network (J12)
Label
Description
GND
Input power ground.
GND
Input power ground.
+12V
+12 VDC input voltage, 24W minimum.
AN0
Channel 0 - Analog Input, 12 bit: 0 - 5VDC
AN1
Channel 1 - Analog Input, 12 bit: 0 - 5VDC
GND
Analog input ground.
AN2
Channel 2 - Analog Input, 12 bit: 0 - 5VDC
An3
Channel 3 - Analog Input, 12 bit: 0 - 5VDC
GND
Analog input ground.
TX
RS-232 signal TX
RX
RS-232 signal RX
GND
RS-232 ground
GND
RS-485 ground
B
RS-485 signal B
A
RS-485 signal A
GND
Counter input ground.
CT0
Channel 0 - Pulse counter Input, 0 - 1kHz
CT1
Channel 1 - Pulse counter Input, 0 - 1kHz
GND
Counter input ground.
CT2
Channel 2 - Pulse counter Input, 0 - 1kHz
CT3
Channel 3 - Pulse counter Input, 0 - 1kHz
GND
Digital input ground.
DI0
Channel 0 - Digital input 0-5VDC
DI1
Channel 1 - Digital input 0-5VDC
GND
Digital input ground.
DI2
Channel 2 - Digital input 0-5VDC
DI3
Channel 3 - Digital input 0-5VDC
DO0
Channel 0 - Digital output 0-5VDC TTL
DO1
Channel 1 - Digital output 0-5VDC TTL
DO2
Channel 2 - Digital output 0-5VDC TTL
DO3
Channel 3 - Digital output 0-5VDC TTL
+5V
+5VDC excitation voltage
GND
Digital output ground
1W
1-Wire network signal. Maximum 50 unique sensor ID's.
GND
1-Wire network reference.
+5V
1-Wire excitation devices for Intellergy powered devices.
12