intellergy sensor controller setup manual
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
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