Installation and Operation Manual. INTEGRA BTU Meter System

Transcription

1 INTEGRA BTU Meter System Meter 1/4 Supply Temp. [F] Return Temp. [F] Flow [gal/min] Energy Rate [kbtu/h] 2.84 Energy Total [kbtu] ß á à Overview Meter 1 Total [kbtu] Meter 2 Total [kbtu] Meter 3 Total [kbtu] 6583 Meter 4 Total [kbtu] 989 ê V1.3

2 Copyright 2017 Integrasense, Inc. Page ii

3 Table of Contents Overview... 5 Installation... 8 Mechanical Installation... 8 Electrical Installation... 8 Power... 8 Flow Meter... 9 Temperature Sensors... 9 Pulse Output... 9 Communications Configuration Operation Appendix A - Modbus Holding Registers Appendix B - Dimensions / Connections Page iii

4 Page iv

5 Overview The INTEGRA BTU Meter Series is a cost-effective, feature-rich modular system designed for submetering applications. It is used to measure energy consumption in almost any liquid heating/cooling system in residential and commercial buildings. Additionally, performance of energy saving programs and the degradation of system efficiency can be monitored. The system consists of DIN-Rail mounted BTU Meter Modules and optional HMI Meter Displays. BTU Meter Modules provide inputs for supply and return temperature sensors (PT1000, 3-wire) and for a flow meter (with either pulse output or 4-20mA current loop output). Module outputs include an energy pulse output (solid state relay) and 12VDC auxiliary power. Modbus RTU (RS-485) communication is standard. The change in temperature between the supply and return fluid lines and the measured fluid flow are used to calculate heating or cooling energy. The BTU algorithm supports multiple aqueous solutions of Ethylene Glycol fluids: 0 (pure water), 10, 20, 30, 40, 50 and 60 volume %. A Windows Utility is used to easily configure BTU Modules via the RS-458 communication port. Flow Computes Energy Rate and Energy Supply Temperature Return Temperature Control or Monitoring System Page 5

6 BTU Meter Modules can be daisy-chained and connected directly to control and/or monitoring systems (Modbus RTU Master). Temperature sensor values, flow, energy rate, total energy, status, meter configuration are available as Modbus Holding Registers. See Appendix A for details. PLC, SCADA, RTU, BAS/BMS BTU Meter Modules (Modbus Slave) Modbus RTU Master Configuration 1: Without local HMI Page 6

7 Optional HMI touch screen modules can provide visual indication of mode (heating/cooling), communication status (online/offline), temperature values, flow, energy rate and total energy consumption. The HMI Module provides two RS-485 ports and is both a Modbus RTU master (communicating with Meter Modules) and slave (for control/monitoring system communication). Each HMI module supports up to 4 BTU Meter Modules. HMI Modules don t need to be programmed; they will automatically discover connected Meter Modules, display their values and make them available to the control/monitoring system. In this configuration BTU Meter Modules connected to an HMI have to have Modbus Device IDs 1 to 4, baud rates set to and a data format of 8N2. Temperature sensor values, flow, energy rate, total energy, status, meter configuration of all connected BTU Meters are available as Modbus Holding Registers. See Appendix A for details. Control/Monitoring System Modbus RTU Master Up to 4 BTU Meter Modules per HMI Meter 1/4 Supply Temp. [F] Return Temp. [F] Flow [gal/min] Energy Rate [kbtu/h] 2.84 Energy Total [kbtu] ID: 1 ID: 2 ID: 3 ID: Baud Rate Data Format 8N2 ß á à Meter 1/4 Supply Temp. [F] Return Temp. [F] Flow [gal/min] Energy Rate [kbtu/h] 2.84 Energy Total [kbtu] ID: 1 ID: 2 ID: 3 ID: Baud Rate Data Format 8N2 ß á à Configuration 2: With local HMI Module Page 7

8 Installation Mechanical Installation BTU Meter Modules are DIN-Rail mountable, inside electrical enclosures. BTU Meter Displays are designed for through panel mounting (e.g. on enclosure doors). Refer to Appendix B for a to-scale cutout template. Both units are powered by efficient supplies, generating little heat and don t require ventilation. Electrical Installation Power BTU Meter Modules and BTU Meter Displays require 14-34VDC (fused) to operate. 14VDC - 34VDC 200mA 24V DC IN RTD Supply Power Terminal blocks are mechanically coded and removable by inserting a screwdriver into the pocket at the release lever and lifting it up (top terminals) or down (bottom terminals). Blk Red Blk NC RTD Return Blk Red Blk NC 12VDC 100mA 5VDC - 50VDC 100mA Pulse OUT 12VDC OUT - + 5VDC - 24VDC 10mA Pulse IN mA IN + - RS-485 GND A+ GND B- Jumper enables 120 Ohm RS-485 EOL Resistor Page 8

9 Flow Meter BTU Meter Modules can accept either two-wire pulse signals or 4-20mA analog signals. The flow pulse input is opto-isolated and current is automatically limited to 10mA. The low impedance (50 Ohm) 4-20mA input is not isolated. Both input signal can be scaled using the provided Windows utility. 4-20mA Open Collector Pulse Output Pulse IN mA IN + - Pulse IN mA IN VDC to +24VDC 10mA - Loop Power Supply + 0V Temperature Sensors The BTU Meter Module accepts 3-wire PT1000 RTDs. This allows for longer sensor cable runs compared to 2-wire, low-impedance sensors. RTD Supply Blk Red Blk NC RTD Return Blk Red Blk NC Pulse Output The BTU Meter Module features one solid state form A relay. The output is electrically isolated. Switching voltage can be supplied using the internal 12VDC power source or any 5-50VDC external source. Depending on configuration, the output generates a pulse every kbtu or MBTU. 12VDC 100mA 5VDC - 50VDC 100mA Pulse OUT 12VDC OUT - + Mechanical or Electronic Counter or Indicator Light Page 9

10 Communication BTU Meter Modules provide a built-in Modbus RTU RS-485 port to communicate with control and or montoring systems like PLCs, HMI, SCADA, BAS/BMS. The module is a Modbus RTU slave device. The Modbus baud rate, data format and device ID are DIP-switch configurable. DIP Switches Power Baud Rate Data Format Device ID N2 Modbus ID = E1 8O1 CONF 8N2 Modbus ID = 2 Modbus ID = RS-485 GND A+ GND B- Insert Jumper to enable 120 Ohm RS-485 EOL Resistor BTU Meter Modules are daisy-chained as shown below. A 120 Ohm end-of-line resistor can be enabled by inserting a jumper in the provided location. Connect cable shields to GND. RS-485 GND A+ GND B- RS-485 GND A+ GND B- RS-485 GND A+ GND B- Enable EOL Resistor To Modbus Master Page 10

11 Configuration Data Format CONF 8N2 RS-485 to USB Converter BTU Meter Modules can be configured using the BTU Meter Windows Utility program. A RS-485 to USB converter has to be used to connect the PC to the Modbus RTU network. The RS-485 converter will appear as a Serial Com Port in Device Manager. Meter configuration parameters can only be changed if the Data Format DIP Switches are set in the up position (see illustration above). After launching the Meter Utility, select the serial com port in the drop down list. Select baud rate, Data Format Config and the Modbus ID of the meter to be configured. Click the Connect button. If all settings are correct, the meter s settings and real-time values are displayed. Mode: Possible selections are Heating or Cooling. Flow Input Source: Flow Meters with 4-20mA analog output or Pulse output can be used. Alternatively, the flow meter value can be provided as a Modbus Holding Register. The Max Flow value is used for scaling. Meter Location: Possible selections are Supply and Return. Supply and Return Temperature readings can be offset individually (positive values only) to make similar sensors a matched pair at operating temperature. Page 11

12 Minumum Flow: For Flow Meters with Pulse Output, the value determines the minimum flow value that is considered Zero flow. For Flow Meters with 4-20mA output, the value determines the flow at 4mA. Maximum Flow: specifies the flow at 20mA for Flow Meters with current output. Flow Offset can be used to shift the flow curve to achieve better accuracy for some non-linear flow meters with pulse output. The following formula applies: Flow [gal/min] = (Freq [pulses/sec] + Flow_Offset [pulses/sec]) * 60 / Pulses_per_Gallon Available Rate Units are: BTU/h, kbtu/h, BTU/min, RT Available Energy Units are: kbtu and MBTU. Volume % Ethylene Glycol: Possible selections are 0%, 10%, 20% 30%, 40%, 50%, 60%. Use 0% for pure water. The meter s temperatures, flow, energy rate and energy are displayed below the configuration settings. The text box below the meter s real-time values contains potential error messages. Error messages are maintained in the BTU Meter Module until the are reset by checking the Reset BTU Meter Errors check box. After all BTU configuration parameters are set and its correct function has been validated, set the Data Format DIP switched from CONF to the desired data format to write protect the configuration settings. Page 12

13 After power is supplied to the BTU Meter Modules the HMI Display can be powered up. It will discover all connected (up to 4) BTU Meter Modules and display their values. The initial page shows the sensor and energy data of the first discovered Meter. Touching the right arrow icon will bring up the page for the next meter. Touching the left arrow icon will go to the previous meter. Touching the up arrow icon will display an overview page containing the Total Energy values of all connected meters. If the meter values are shown in red, the meter is in heating mode. If the values are shown in blue, the meter is in cooling mode. If the values are dark grey, The meter is offline (not communicating). Meter 1/4 Supply Temp. [F] Return Temp. [F] Flow [gal/min] Energy Rate [kbtu/h] 2.84 Energy Total [kbtu] ß á à Overview Meter 1 Total [kbtu] Meter 2 Total [kbtu] Meter 3 Total [kbtu] 6583 Meter 4 Total [kbtu] 989 ê T Heating Cooling Not communicating Page 13

14 Appendix A - Modbus Holding Registers BTU Meter Module Register # Description Data Type 0/1 Access Maximum Flow in gal/min (used for scaling) 32 bit swap float read/write 2/3 Minimum Flow in gal/min (used for scaling) 32 bit swap float read/write Configuration Registers (can only be written to when Data Format DIP Switches are set to CONF ) 4/5 Flow Offset (Pulses per Second) 32 bit swap float read/write 6/7 Pulses per Gallon (used for pulse input scaling) 32 bit swap float read/write 8 LowByte: Flow Input Source, HighByte: Glycol % 16 bit int read/write 9 Temp. Offset (1/100 degf). Positive values only. 16 bit int read/write 10 LowByte: Meter Location, HighByte: Rate Units 16 bit int read/write 11 LowByte: Mode, HighByte: Energy Units 16 bit int read/write 12/13 Supply Temp. (degf) 32 bit swap float read 14/15 Return Temp. (degf) 32 bit swap float read 16/17 Flow (gal/min) 32 bit swap float read/write 18/19 Energy Rate 32 bit swap float read 20/21 Energy Counter 32 bit unsigned int read 22 Fault Conditions 16 bit int read/write 23 Modbus Error Counter 16 bit int read 24 Heartbeat Counter 16 bit int read 25 Energy Counter Fraction 16 bit int read HMI Meter Display HMI Displays provide the same Modbus Holding Registers as BTU Meter Modules for up to four Meters. The Holding Register block for Meter 1 starts at address 0. For Meter 2 at address 26, etc. BTU Meter configuration settings can not be changed through the HMI Display. Page 14

15 Appendix A - Modbus Holding Registers Registers 0 to 7: The Maximum Flow register value (registers 0/1) specifies the flow at 20mA for Flow Meters with current output. The Minimum Flow registers (registers 2/3): Flow Meters with Pulse Output: The register value determines the minimum flow value that is considered Zero flow. Flow Meters with 4-20mA Output: The register value specifies the flow at 4 ma. The Flow Offset registers (registers 4/5) can be used to shift the flow curve to achieve better accuracy for some non-linear flow meters. The following formula applies (where Pulses_Per_Gallon is the value of registers 6/7): Flow [gal/min] = (Freq [pulses/sec] + Flow_Offset [pulses/sec]) * 60 / Pulses_per_Gallon Register 8: LowByte (Flow Input Source): 4 0: 4-20mA 4 1: Pulse 4 2: Modbus HighByte (Glycol Volume Percentage): 4 0: Pure Water 4 1: 10% Ethylene Glycol 4 2: 20% Ethylene Glycol 4 3: 30% Ethylene Glycol 4 4: 40% Ethylene Glycol 4 5: 50% Ethylene Glycol 4 6: 60% Ethylene Glycol If the Flow Input Source is Modbus (value = 2), the Flow register (14/15) values are read and used to compute Energy Rate and Energy. If the Flow Input Source is 4-20mA or Pulse, the Flow register (14/15) values represent the current calculated flow. Register 9: The Temperature Offset register contains an 8bit value (low Byte: ) for the Supply Temperature offset and an 8bit value (high Byte: ) for the Return Temperature offset. Both positive values are in 1/100 of degrees Fahrenheit (e.g a value of 222 equals 2.22 deg.f). Page 15

16 Appendix A - Modbus Holding Registers Register 10: LowByte (Location): 4 0: Return 4 1: Supply HighByte (Rate Units): 4 0: BTU/h 4 1: kbtu/h 4 2: BTU/min 4 3: RT (Refrigeration Tons) Register 11: LowByte (Mode): 4 0: Cooling 4 1: Heating HighByte(Energy Units): 4 0: kbtu 4 1: MBTU Register 20: Meaning of Fault Conditions register values: 4 1: Supply Temp. Sensor Fault 4 2: Return Temp. Sensor Fault 4 4: Flow > max Flow 4 8: Flow Input Source register value invalid 4 16: Meter Location register value invalid 4 32: Mode register value invalid 4 64: 4-20mA Input Fault 4 128: Heating and Ts<Tr or Cooling and Ts>Tr. Each fault condition is represented by a bit of the Fault Conditions register. Fault conditions are retained until reset/power cycle. The register can be reset by writing a value of zero to it. The Modbus Error Counter register maintains the number of Modbus Errors since startup. Page 16

17 Appendix B - BTU Meter Module Dimensions 105.7mm (4.16 ) 117.2mm (4.61 ) 107mm (4.21 ) 113.6mm (4.47 ) 22.5mm (0.89 ) Electrical Installation 14VDC - 34VDC 200mA 24V DC IN RTD Supply Blk Red Blk NC Power Baud Rate 4800 Data Format 8N2 Modbus ID = 1 Device ID VDC - 50VDC 100mA RTD Return Blk Red Blk NC 12VDC 100mA Pulse OUT 12VDC OUT E1 8O1 CONF 8N2 Modbus ID = 2 Modbus ID = VDC - 24VDC 10mA Pulse IN mA IN + - RS-485 GND A+ GND B- Jumper enables 120 Ohm RS-485 EOL Resistor Page 17

18 Appendix B - HMI Meter Display Dimensions Electrical Installation Baud Rate Data Format Device ID N2 Modbus ID = DIP Switches VDC Power E1 8O1 8N1 Modbus ID = 2 Modbus ID = EOL Resistor RS 485 To Modbus Master To BTU Meters A+ B- GND A+ B- GND RS " Fixed: baud 8N2 2.82" 2.49" 1.65" 1.20" RS-485 EOL Resistor Power Page 18

19 Appendix B - HMI Meter Display Panel Cutout Template (to scale) Top 2.68" 0.77" 3.66" 1.27" 1.13" 0.73" 0.59" 0.64" 0.24" 0.10" 2.36" Inside of Front Panel Do not over tighten mounting screws! Page 19