CAM KIT FIELD INSTALLATION GUIDE Quick Installation Guide

Transcription

1 CAM KIT FIELD INSTALLATION GUIDE Quick Installation Guide PBN Controls Inc. Tech Support: +1 (866) Tech Mobile: +1 (905) This guide should serve as the installation guide for the PBN Controls CAM kit installation. Robert Beer Software Development Manager 3/23/2018

2 Contents CONTENTS DOCUMENT REVISION HISTORY DEFINITIONS & ACRONYMS IOT KIT DATA ACQUISITION OBJECTIVE (CPC - EMERSON) KIT CONNECTIONS AND POWER OUTLET OVERVIEW HARDWARE COMPONENTS AND IDENTIFICATION KEYBOARD, VIDEO, MOUSE - OVER ETHERNET CAT RS 485 SERIAL CONVERTER INSTALLATION POWERING AND CONNECTION TO DATALOGGER SERIAL CONNECTION TO KMTRONIC RELAY: SERIAL CONNECTION TO CPC: IF ON RMCC REFLECS CPC CONTROLLER: ADDITIONAL RACK CONTROLLER CONNECTIONS: TCP/IP NETWORK CONFIGURATION ETHERNET CABLING THINGS YOU LL NEED TO COMPLETE THE INSTALLATION TP-LINK NETWORK SWITCH POWER CABLING AND POWER OUTLETS DATALOGGER COMPUTER CRADLEPOINT CELLULAR MODEM/ROUTER (IBR 650) INSTALLING DENT POWERSCOUT POWER METERS * CHANGING IP ADDRESS ON POWERSCOUTS NETWORK CABLING MICROTHERMO USB/ETHERNET DONGLE MICROTHERMO 2 ND NIC ETHERNET PORT UPON COMPLETION PLEASE CALL PBN CONTROLS INC INSTALLING THE KMTRONIC RELAY CPC PROGRAMMING FOR BACKUP ALARMS ALARM TESTING UPON COMPLETION PLEASE CALL PBN CONTROLS INC Tech Support: +1 (866) Tech Mobile: +1 (905)

3 8.1. APPENDIX EXAMPLE POWER METER FORM POWER METER # FORM POWER METER # FORM POWER METER # FORM POWER METER # FORM COMPRESSOR DETAIL FORM # COMPRESSOR DETAIL FORM # Document Revision History Description of Changes Version Author Date Initial Draft Version Draft 0.1 Rob Beer Mar. 23 rd, 2018 Serial and CPC connection information added from Matt C. Draft 0.2 Rob Beer Apr. 5 th, 2018 Added KVM and some tidying Initial 1.0 Rob Beer Apr. 6 th, 2018 Added Matt s CPC and KMTronic Hookup info Initial 1.05 Rob Beer Apr. 11 th, 2018 Added Matt s IP Address change information for meters Initial 1.1 Rob Beer Apr. 14 th, 2018 Added Cradlepoint network icon and booster antenna info Initial 1.2 Rob Beer Apr. 18 th, 2018 Added CPC Alarm Backup Programming Initial 1.3 Rob Beer June. 7 th, Definitions & Acronyms Term Definition Dent Manufacturer of power meters i.e.: PowerScout 24 & 37 Site A facility installed at the client site where data is collected and transferred to cloud/pbn Controls Client A PBN Controls Inc. customer WPS Web Power Switch (Remote Power Management) Networked Power IoT Internet of Things IT Information Technology UPS Uninterruptible Power Supply APC Manufacturer of Uninterruptible Power Supplies Datalogger Networked Data Acquisition Computer PC Personal Computer used interchangeably with Datalogger NIC Network Interface Card (AKA Network Card/Network Port) KVM Keyboard Video Mouse Tech Support: +1 (866) Tech Mobile: +1 (905)

4 3. IoT Kit Data Acquisition Objective (CPC - Emerson) This kit will monitor the performance and relay the information from both the CPC - Emerson installation as well as energy metering information from the accompanying Dent PowerScout MODBUS energy meters. 4. Kit Connections and Power Outlet Overview Figure 1 Network Overview Tech Support: +1 (866) Tech Mobile: +1 (905)

5 5. Hardware Components and Identification A breakdown of the components in the kit. Each component comes with their own installation instructions in their respective boxes. See next page. Tech Support: +1 (866) Tech Mobile: +1 (905)

6 Figure 2 - Web Power Switch Figure 3 PowerScout 3037 Figure 4 - DataLogger Computer Figure 5 Dent PowerScout 24 Figure 6 - TP Link Network Switch Figure 7 - CradlePoint Cell Modem Router Figure 8 - KMTronic RS485 8 CH Relay Figure 9 - USB to RS 485 Serial Converter Figure V AC 12V DC Adapter Tech Support: +1 (866) Tech Mobile: +1 (905)

7 5.1. Keyboard, Video, Mouse - Over Ethernet Cat 6 The KVM Extender allows the manager to interface and control the CAM Datalogger from the comfort of their office. Machine Room KVM A Local Unit KVM Cable No KVM Power Adapter (Powered by USB!) Plug the cable with the USB dongle into the Datalogger PC Manager s Office KVM B Remote Unit KVM Cable KVM Power Adapter Figure 11 - Machine Room Local Unit A Figure 12 - Manager's Office Remote Unit B Local Unit A o Install KVM in machine room o Install Keyboard, Mouse, and monitor in machine room on top of cabinet o Connect Monitor, USB Keyboard, USB Mouse for machine room to Local Unit A o Connect specialized KVM cable with USB dongle to Datalogger PC (grey connector to grey port) CRITICAL Power Local Unit A via USB dongle (attached to specialized cable) to datalogger PC o Press Local Unit button (mode cycle) on the top of the unit until it flashes back and forth (this allows either the machine room or the manager s office to control the computer) o To take control of the computer click the left mouse button to activate Remote Unit B o Install KVM in Manager s office o Install Keyboard, Mouse, and monitor in Manager s office Tech Support: +1 (866) Tech Mobile: +1 (905)

8 o o o o Connect Monitor, USB Keyboard, USB Mouse for manager s office to Remote Unit B Power the unit with the power cable & transformer included in the box Press Local Unit button (mode cycle) on the top of the unit until A light indicator is on. (this indicates that I want to control the datalogger PC at Local Unit A) To take control of the computer click the left mouse button to activate Connecting them together o Run Ethernet cables (provided), using Ethernet coupling(s) (provided, if necessary) from Local Unit A to Remote Unit B Configuration o All of the configuration for the configuration of this device was done and set up at PBN Controls Inc. (Check the accompanying manual if necessary) 5.2. RS 485 Serial Converter Installation Powering and connection to Datalogger 1) Take USB AB cable (included in serial converter box) and connect to the available port on the Serial converter. 2) Take other end of cable and connect to available USB port on Datalogger. 3) Connect supply power to DC-IN on the Serial converter. (If it does not power on right away try swapping the connections for correct polarity) Figure 13 Conn From Each CPC Figure 14 Conn From Relay Figure 15 Conn To Relay Tech Support: +1 (866) Tech Mobile: +1 (905)

9 Serial connection to KMTronic Relay: 1) Run 18/2 shielded wire from KMTronic Relay to Serial converter. 2) At the KMTronic relay connect the black wire to B on the relay beside the power input. 3) Connect the white wire to A on the relay. 4) Connect ground wire to ground connection on the relay. 5) At the Serial converter make the following connections on the D4 connection (labeled Relay). 6) Connect black wire to TxD- (Data-). 7) Connect white wire to TxD+ (Data+). 8) Connect ground wire to GND (ground). 9) Power KMTronic relay with supplied transformer labeled Relay. 10) Connect the black wire from the transformer to the connection on the relay. 11) Connect the red wire to + on the relay Serial Connection to CPC: 1) Run 18/2 shielded wire from Serial Converter to CPC Controller. 2) Connection for Rack A will be on D1 (labeled COMM 1) of the Serial converter. 3) At the Serial converter connect the black wire to RxD+ (TxD). 4) Connect the white wire to RxD- (RxD). 5) Connect the ground wire to GND. If on Einstein 2 CPC controller: 1) On the inside of the CPC controller locate the RS485-COMM2 A connector at the bottom left. 2) With the control wires coming from the Serial converter connect the black wire to the - connection on the right. 3) Connect the white wire to the + connection on the left. 4) Connect the ground wire to the 0V connection in the middle. Figure 16 - Einstein 1 Figure 17 Einstein 2 Figure 18 Einstein 3 Tech Support: +1 (866) Tech Mobile: +1 (905)

10 If on RMCC Reflecs CPC controller: 1. On the inside of the CPC controller locate the COM A connector at the bottom left. 2. With the control wires coming from the Serial converter connect the black wire to A- connection. 3. Connect the white wire to A+ connection. 4. Connect ground wire to 0V connection. Figure 19 - Reflecs 1 Figure 20 Reflecs 2 Figure 21 Reflecs Additional Rack Controller connections: 1) Copy the above steps but for Rack B. Use the same COM A connector at the bottom left, but this time we change the connection points on the Serial converter to D2 (labeled COMM 2 instead of D1). 2) Rack C & D are similar. (If you require 4 COMM ports an 8 Port USB/RS 485 Connecter will be sent with your kit instead of a 4-port one) 5.3. TCP/IP Network Configuration The local network is designed to run plug and play. Each port and power slot are PRECONFIGURED and MUST BE USED AS INDICATED! As there is NO DHCP server on the network -- each IP address must be set to a static IP manually. Device Name Network Subnet Mask Default Gateway Local Network Configuration / To test connectivity between machines, use a laptop and ping the other IPs to assure connectivity. Tech Support: +1 (866) Tech Mobile: +1 (905)

11 5.4. Ethernet Cabling Each port of the TP Link network switch should be clearly labelled as to which device ought to be plugged into which port. They MUST be connected to the ports properly since the network switch s ports and traffic can be controlled independently. (See Figure 1 Network Overview) If there s no suitable markings on the TP-Link Network Switch use this layout for each network port: (otherwise follow the port labelling as they are factory named and configured properly). Net Switch Port # Device Name IPv4 Address 1 CradlePoint Cellular Modem Datalogger Industrial Computer Web Power Switch (RPM) Rack A CPC Controller (E2 only) Rack B CPC Controller (E2 only) Dent PowerScout 24 Meter # Dent PowerScout 24 Meter # Dent PowerScout 37 Meter # All of the components will have their network configurations set and tested at the factory; except the Dent PowerScout meters (if they were ordered from another supplier). If they were ordered from PBN Controls (not in bulk) Things You ll Need to Complete the Installation Ideally you should have access to a Microsoft Windows-based laptop to complete the installation, especially if you need to change the IP addresses on the Dent PowerScouts on site or beforehand TP-Link Network Switch The TP-Link managed network switch s configuration is set PBN Controls Inc. to: Device Name IPv4 Address Subnet Mask Default Gateway TP Link Network Switch For additional connection information (See Figure 1 Network Overview) Power Cabling and Power Outlets Each port should be clearly labelled as to which device ought to be plugged into it. Tech Support: +1 (866) Tech Mobile: +1 (905)

12 Figure 22 - Network Switch Port Assignment Figure 23 - Power Management Port Assignment 5.8. Datalogger Computer The TP-Link managed network switch s configuration is set PBN Controls Inc. to: Device Name IPv4 Address Subnet Mask Default Gateway Datalogger Computer * *and also for dataloggers with 2 network ports. USE (default) and not CradlePoint Cellular Modem/Router (IBR 650) The CradlePoint cellular modem/router s configuration is set PBN Controls Inc. to: Device Name IPv4 Address Subnet Mask Default Gateway CradlePoint Router Modem The CradlePoint cellular modem/router provides all of the connectivity of all the components to the Internet. Plug the network cable into the NETWORK Port of the CradlePoint denoted by a network icon. Instead of the paddle antenna use the external omni-directional antenna Installing Dent PowerScout Power Meters * * The Dent Power meter s configuration is set PBN Controls Inc. to: Meter ID IPv4 Address Subnet Mask Default Gateway Tech Support: +1 (866) Tech Mobile: +1 (905)

13 Meter Meter Meter Meter * This is only applicable if Dent power meters are purchased from PBN Controls Inc. for the particular installation project. Dent power meters bought in bulk or elsewhere, they will have IP addresses unassigned and must be assigned on site as per the information provided above. Figure 24 - Installed PowerScout Changing IP Address on PowerScouts Instructions for Dent PowerScout IP Address configuration changes: 1. Download the Viewpoint program from Dent on the PC or laptop that you will be using to configure the Dent Powerscout Open the file and complete the software install. When the installation is complete open Viewpoint. 3. On the Viewpoint Communications tab select USB/RS-485 as your communication. 4. With a USB-AB cable connect the PowerScout to the PC. 5. Left click on the drop-down menu under PC COM port and select the COM port labeled DENT USB. 6. Left click connect at the bottom right of the window. 7. Left click the COMM s Setup tab at the top of the window. 8. Ensure Communication Mode is set to Modbus. 9. Under Ethernet Settings change the IP Address to the applicable address for the meter. Ex: Ensure subnet mask is Change the gateway address to: Left click send setup to meter Tech Support: +1 (866) Tech Mobile: +1 (905)

14 Figure 25 - Dent IP Address 1 Figure 26 - Dent IP Address 2 Important Dent Links: PowerScout Series Installation instructions: Current Sensor Installation instructions: Software Downloads Power meter form to be completed by installation technician is found in Appendix A to this document. A completed Sample power meter setup form is included as well as an example in Appendix A. Be sure to install the CTs correctly, paying attention to the directionality of the CTs. Cont Tech Support: +1 (866) Tech Mobile: +1 (905)

15 DO NOT REDUCE WIRE GUAGE FOR LONGER RUNS FOR THE CTS YOU MUST CONTINUE TO USE 18/2 FOR EXTENSIONS UP TO 500. Tech Support: +1 (866) Tech Mobile: +1 (905)

16 5.11. Network Cabling Proper cabling and lengths should have been included in the kit for your installation MicroThermo USB/Ethernet Dongle If your kit did not come with this dongle or if you re installing this kit at a new location skip this step and go to OPTIONAL Use the USB/Ethernet Dongle to plug into the MicroThermo Controller PC in the back of the machine. Install the driver on the MicroThermo Controller PC in Microsoft Windows. Configure the network port as follows: Device Name IPv4 Address Subnet Mask Default Gateway Secondary MicroThermo Network MicroThermo 2 nd NIC Ethernet Port *Log on to the MicroThermo computer and configure the 2 nd Ethernet port to connect to our computer. Install the driver on the MicroThermo Controller PC in Microsoft Windows. Configure the network port as follows: Device Name IPv4 Address Subnet Mask Default Gateway Secondary MicroThermo Network Upon Completion Please Call PBN Controls Inc. PBN Controls will go through the meter readings and confirm connectivity for all of the components. support@pbncontrols.com Tech Support: +1 (866) Tech Mobile: +1 (905) The installer MUST call PBN Controls Inc. to validate the installation components. The installer MUST complete the following sheets regarding the CTs for the power meters. Tech Support: +1 (866) Tech Mobile: +1 (905)

17 6.1. Installing the KMTronic Relay The KMTronic relay is used to trap alarms from the CAM system, sends them to the CPC, which in turn sends them to the appropriate strobe/light, strobe/light/siren, and building relay (alarm monitoring company). CPC to KMTronic relay alarm setup Prior to programming the CPC, locate and take note of 3 (ideally sequential) available input points. For this example, we will be using Input Board 1, points 1, 2, and 3. The installer will also need to locate the outputs used for the horn/strobe, non-critical strobe and building alarm company. For this example, we will use Output board 2, points 4, 5, and 6 respectively. 1. Create a new application in the E2 by pressing Menu (F9) -> Add/Delete Application (6) -> Add Application (1) 2. In the add application menu select Digital Sensor Ctrl for type. 3. Select 3 to be created and press enter. You will be asked if you would like to edit new applications now, select yes and you will be brought to the setup menu for the first digital sensor ctrl. 4. Rename the application to CAM Critical. 5. Press F2 to move to the Inputs tab. Select one of the spare inputs found earlier. Ex: Input board 1, point Press F2 until you get to the Outputs tab. For Command Out select the appropriate output for the Horn/Strobe. Ex: Output board 2, point In the same Outputs tab ensure that Cmd When On value is On and Cmd When Off value is Off. 8. Press Menu(F9) -> Configured Applications (5) -> Sensor Ctrls (4) to get to the Sensor Ctrls menu. 9. Locate one of the other applications created earlier. It will be labeled similar to Dig Sensor001. Ensure that the digital sensor application you have selected is not already in use. It should have no inputs or outputs linked to it. 10. Rename the application CAM Non-Crit 11. Navigate to the Inputs tab. Select one of the other spare inputs. Ex: Input board 1, point Navigate to the Outputs tab. For Command Out select the appropriate output for the non-critical strobe. a. Ex: Output board 2, point In the same Outputs tab ensure that Cmd When On value is On and Cmd When Off value is Off. 14. Navigate back to the Sensor Ctrls menu and locate the 3rd application that was created previously. 15. Rename the application CAM Building 16. Navigate to the Inputs tab. Select one of the other spare inputs. Ex: Input board 1, point Navigate to the Outputs tab. For Command Out select the appropriate output for the building alarm company. a. Ex: Output board 2, point In the same Outputs tab ensure that Cmd When On value is On and Cmd When Off value is Off. 19. Run an 18 AWG shielded wire from the #1 NO relay point on the KMTronic to the input assigned to Cam Critical. Ex: Input board 1, point 1 Tech Support: +1 (866) Tech Mobile: +1 (905)

18 20. Run an 18 AWG shielded wire from the #2 NO relay output on the KMTronic to the input assigned to CAM Non-Crit a. Ex: Input board 1, point Run an 18 AWG shielded wire from the #3 NO relay output on the KMTronic to the input assigned to CAM Building. a. Ex: Input board 1, point CPC Programming For Backup Alarms For these instructions we will be assuming that Rack A E2 is the controller responsible for CAM Critical alarm outputs to the building alarm and horn. On Rack A Controller create two new applications for Digital Sensor Ctrls. Name one of them Rack A Alarm and the other Rack B Alarm. Go to the alarm filtering set up for Rack A (F9, 7, 5, 2). Move to the alarm Outputs tab. Press F3 to edit and select Alternate I/O Formats (1) and choose Area Ctrl: Application: Property (2). Under Area Ctrl select Rack A, Application select Rack A Alarm, Input select LOGIC IN1 Go to the set up for Rack A Alarm created earlier and ensure that LOGIC IN1 on the Inputs page is set to Rack A: ADVISORY SERV: ALARM OUTPUT The backup for Rack A Alarm is now complete, moving on to Rack B. On Rack B go to the global data menu (F9, 7, 8) and find a digital output that is not being used. For this example we will use SPARE DIG8 OUT. Open the setup menu and scroll down to Spare Dig8 Mode: and set to Primary so that it is supplying the global data point. Navigate to the alarm setup for Rack B (F9, 7, 5, 2) and move to the Outputs tab. Press F3 to edit and select Alternate I/O Formats (1) and choose Area Ctrl: Application: Property (2). Under Area Ctrl select Rack B, Application select GLOBAL DATA, Input select SPARE DIG8 IN Navigate back to the Global Data setup and ensure that SPARE DIG8 IN is Rack B: ADVISORY SERV: ALARM OUTPUT Go back to Rack A and check the Global Data setup. Ensure that Spare Dig8 Mode is set to User. Go to the Rack B Alarm program created previously and navigate to the Inputs tab. Under Area Ctrl select Rack A, Application select GLOBAL DATA, Output select SPARE DIG8 OUT Tech Support: +1 (866) Tech Mobile: +1 (905)

19 7.1. Alarm Testing Go to CAM Critical sensor ctrl program and navigate to the Inputs tab. For LOGIC IN2 select Rack A: Rack A Alarm: COMMAND OUT For LOGIC IN3 select Rack A: Rack B Alarm: COMMAND OUT Simulate an alarm on each rack one at a time and ensure that the CAM Critical sensor ctrl changes to ON when the alarms are triggered and the horn and building alarms are triggered. After testing is completed delete the links created for LOGIC IN2 and LOGIC IN3 in CAM Critical program so that only the KMTronic input is triggering CAM Critical. If the event arises that the CAM system is non-operational, recreate the links and ensure that alarms created on the CPC E2s for each rack trigger the building alarm and horns. 8. Upon Completion Please Call PBN Controls Inc. PBN Controls will go through the meter readings and confirm connectivity for all of the components. support@pbncontrols.com Tech Support: +1 (866) Tech Mobile: +1 (905) The installer MUST complete the following sheets regarding the CTs for the power meters. The installer MUST call PBN Controls Inc. to validate the installation components and Assure the MODBUS readings as set up properly. Take pictures of the following forms then them to support@pbncontrols.com or text to (905) or fax them to: (905) ATTN: PBN Installation Support Appendix Example Power Meter Form Tech Support: +1 (866) Tech Mobile: +1 (905)

20 Power Meter # Form Meter Number: IP Address: Subnet mask: Default Gateway: Element A 1-Phase 3-Phase Element E 1-Phase 3-Phase Rack A Mains Line #1 Rack A SGr1 Compressor #1 200 Amp Split Core 50 Amp Mini Hinge Rack A Mains Line #2 Rack A SGr1 Compressor #2 200 Amp Split Core 50 Amp Mini Hinge Rack A Mains Line #3 Rack A SGr1 Compressor #3 200 Amp Split Core 50 Amp Mini Hinge Element B 1-Phase 3-Phase Element F 1-Phase 3-Phase Rack A Condenser Mains Line #1 Rack A SGr2 Compressor #1 50 Amp Split Core 50 Amp Mini Hinge Rack A Condenser Mains Line #2 Rack A SGr2 Compressor #2 50 Amp Split Core 50 Amp Mini Hinge Rack A Condenser Mains Line #3 Rack A SGr3 Compressor #3 50 Amp Split Core 50 Amp Mini Hinge Element C 1-Phase 3-Phase Element G 1-Phase 3-Phase Rack B Mains Line #1 Rack B SGr1 Compressor #1 200 Amp Split Core 50 Amp Mini Hinge Rack B Mains Line #2 Rack B SGr1 Compressor #2 200 Amp Split Core 50 Amp Mini Hinge Rack B Mains Line #3 Rack B SGr1 Compressor #3 200 Amp Split Core 50 Amp Mini Hinge Element D 1-Phase 3-Phase Element H 1-Phase 3-Phase Rack B Condenser Mains Line #1 Rack B SGr2 Compressor #1 50 Amp Split Core 50 Amp Mini Hinge Rack B Condenser Mains Line #2 Rack B SGr2 Compressor #2 50 Amp Split Core 50 Amp Mini Hinge Rack B Condenser Mains Line #3 Rack B SGr2 Compressor #3 50 Amp Split Core 50 Amp Mini Hinge Tech Support: +1 (866) Tech Mobile: +1 (905)

21 Power Meter # Form Meter Number: IP Address: Subnet mask: Default Gateway: Element A 1-Phase 3-Phase Element E 1-Phase 3-Phase Element B 1-Phase 3-Phase Element F 1-Phase 3-Phase Element C 1-Phase 3-Phase Element G 1-Phase 3-Phase Element D 1-Phase 3-Phase Element H 1-Phase 3-Phase Tech Support: +1 (866) Tech Mobile: +1 (905)

22 Power Meter # Form Meter Number: IP Address: Subnet mask: Default Gateway: Element A 1-Phase 3-Phase Element E 1-Phase 3-Phase Element B 1-Phase 3-Phase Element F 1-Phase 3-Phase Element C 1-Phase 3-Phase Element G 1-Phase 3-Phase Element D 1-Phase 3-Phase Element H 1-Phase 3-Phase Tech Support: +1 (866) Tech Mobile: +1 (905)

23 Power Meter # Form Meter Number: IP Address: Subnet mask: Default Gateway: Element A 1-Phase 3-Phase Element E 1-Phase 3-Phase Element B 1-Phase 3-Phase Element F 1-Phase 3-Phase Element C 1-Phase 3-Phase Element G 1-Phase 3-Phase Element D 1-Phase 3-Phase Element H 1-Phase 3-Phase Tech Support: +1 (866) Tech Mobile: +1 (905)

24 Compressor Detail Form # Tech Support: +1 (866) Tech Mobile: +1 (905)

25 Compressor Detail Form # Tech Support: +1 (866) Tech Mobile: +1 (905)

26 Tech Support: +1 (866) Tech Mobile: +1 (905)