M2 Wireless Gateway and Remotes. Installation and Operations Manual Section 50

Transcription

1 M2 Wireless Gateway and Remotes Installation and Operations Manual Section 50

2 In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time. The latest version of this manual can be found at FW MURPHY has made efforts to ensure the reliability of the M2 Wireless Monitoring System and to recommend safe usage practices in system applications. Please note that in any application, operation and controller failures can occur. These failures may result in full control outputs or other outputs which may cause damage to or unsafe conditions in the equipment or process connected to the M2 Wireless Monitoring System. Good engineering practices, electrical codes, and insurance regulations require that you use independent external protective devices to prevent potentially dangerous or unsafe conditions. Assume that the M2 Wireless Monitoring System can fail with outputs full on, outputs full off, or that other unexpected conditions can occur. BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT: Please read the following information before installing the M2 Wireless Monitoring System. This installation information is intended for M2 Wireless Monitoring System only. Before installing, visually inspect the product for any damage during shipping. Disconnect all power and be sure machine is inoperative before beginning installation. Installation is to be done only by qualified technician. Observe all Warnings and Cautions at each section in these instructions. Device shall be wired in accordance with Class I, Division 2 wiring methods. This equipment is suitable for use in Class I, Division 2, Groups B, C, and D hazardous Areas. WARNING Explosion Hazard Substitution of components may impair suitability for Class I, Division 2. Please contact Murphy immediately if you have any questions.

3 Table of Contents Overview... 1 Basic Components and Key Features of the Gateway... 1 Input/Output Types... 3 Wiring Connections... 3 Input/Output Types and Specifications for the Gateway... 4 Input/Output Types and Specifications for the Remotes... 5 Hardware Installation and Wiring... 7 Mounting the Gateway... 7 Mounting the Remotes... 7 Wiring the Gateway... 8 Wiring the Remote... 9 Using the Gateway and Remote(s) Set-Up Gateway and Remote Operational Setup Menu General Information Battery Installation Remote Battery Voltage Heartbeat Deep Sleep Reset Features Gateway Communications RS485 Port (Serial) Used for user connection RS485 Port (Serial) Emergency Communication Connection Modbus RTU Protocol Modbus Register Map Replacement Parts and Assemblies Accessories M2 Wireless Configuration Tool Software Appendices Gateway LED Description Remote LED Description FCC/IC Compliance, Warnings, & Battery information FCC/IC Compliance Warnings Battery Information MODBUS Register Access... 47

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5 Overview The M2 Wireless system is designed to replace expensive wiring and conduit that is part of outfitting a natural gas compressor system. Typically, a natural gas compressor skid requires conduit and/or tubing between the sensor location, the sensor, and the control panel. By using a low power wireless system, the conduit material and labor is significantly reduced or completely eliminated. Reliability is improved compared to traditional installation practices. Wireless technology provides the ability to remove a significant number of wire connections which over time become intermittent due to chafing and breaking. The M2 Wireless system uses a star type wireless network. This type of topology utilizes a single wireless master, denoted as the Gateway, and multiple slaves, denoted as Remotes. This topology has been chosen because it meets the following requirements: Extremely low power consumption. Near real-time throughput of data from the sensor to the Gateway. User will find references to learning throughout the IOM. This refers to the process of linking the Remotes to the Gateway. This learning identifies a remote to a specific Gateway. Remotes are added or deleted from a system depending on user requirements. Basic Components and Key Features of the Gateway The M2 Wireless system consists of a Gateway module and combination of Remotes connected directly to end-devices. No special cables are required. The M2 Wireless Gateway is designed for use within a weatherproof enclosure only. The Remotes are designed for use in both indoor/outdoor environments. Remote enclosures are CSA approved for indoor and outdoor use. Gateway M2-G-xx Power VDC: 1W typical, 1.1W (max) Storage power able to withstand 12V crank Inputs 1 digital input (DI) Outputs 9 digital outputs (DO) Communications RS485 (Modbus Slave) RF (900 mhz), Gateway(s) Remote(s) Antenna 900mHz Whip Style (Gateway) pcb Loop Style (Remote) Operating Temperature -40 to 85 C (185 F)

6 Hazardous Area Operation The M2 Wireless certifications: CSA, CLASS 1, DIVISION 2, Groups B, C and D are approved. Warning: Explosion hazard Do not disconnect the equipment unless the power has been switched off, or the area is known to be non-hazardous

7 Input/Output Types Wiring Connections NOTE: Maximum power ratings based on all I/O operating in the ON position with 30V supply. Typical based on 24V supply. Gateway Requirements: 10 to 30 VDC: 1.1W (max) There are two screw terminal connectors for power hookup at terminals labeled B+ and B- respectively

8 In the event the unit has power of less than 7.2 volts +/- 0.2 volts, but more than 6.0 volts, Gateway will provide the following LED indication. o The Heartbeat and COP LED s will be activated (on). o Once input voltage is above 7.2 volts, the Heartbeat LED will begin flashing, and the COP LED will turn off. NOTE: Run power directly from battery posts to Gateway power terminals when battery is the power supply. Input/Output Types and Specifications for the Gateway Digital Input Gateway (DI) Number of devices: 1 Device types: discrete input, normally open (N/O), active low, non-incendive. One (1) input, active low, non incendive Input used to reset active faults on Gateway, and reset form C relay upon all remotes returning to a non-faulted condition There is one screw terminal connector for the digital input. Terminal is labeled DI. Discrete Output Gateway (DO) Number of devices: 9 Device types: discrete output Eight (8) FET s, sink B- ( VDC) o Outputs linked to remotes 1-8. Example, output one (1) will energize when remote one (1) is faulted. One (1) relay output, form C, dry contacts ( VDC, VAC) o Output is energized when an active fault is registered with the Gateway o Output linked to status of remotes 9-30 There are three screw terminal connectors for the relay output and one screw terminal connectors for each FET output. Terminals NO-COM-NC are for the relay terminals. Terminals #1 - #8 are for the eight FET terminals. Red LED s give a visual indication of active FET output signal

9 Input/Output Types and Specifications for the Remotes Digital Input Remote (DI) M2-DI Power Requirements: One (1) Lithium, 3.6 VDC AA battery, 120mW (max) Number of devices: 1 Device types: discrete input, normally open (N/O), close circuit to activate, normally closed (N/C), open circuit to activate, non-incendive. Wire input to a dry switch contact only. There are three screw terminal connectors for the digital input. Terminals are labeled (+) sense, (-) common, and N/A. Operating Temperature -40 to 85 C (185 F)

10 Thermocouple Input Remote (TC) M2-TC Power Requirements: Two (2) Lithium, 3.6 VDC AA batteries,120 mw (max) Number of devices: 1 Device types: thermocouple input, type J or K, 24 bit hardware. Use ungrounded thermocouples only. Grounded thermocouples are not supported. Errors in readings with grounded thermocouples can be the result of differences in grounding between devices. Automatic cold junction compensation is built-in. Open thermocouple detection: drives terminal reading high (1371 o C / 2500 o Fmax of scale). There are three screw terminal connectors for each thermocouple. Terminals are labeled (+) yellow or white, and (-) red for thermocouple connection. Operating Temperature -40 to 85 C (185 F)

11 Hardware Installation and Wiring Mounting the Gateway The Gateway can be mounted vertically or horizontally on a standard DIN rail. Two clamp-type feet along the bottom of the controller attach to the DIN rail, however, rail stops are recommended to prevent sliding. Mounting the Remotes The Remotes can be installed directly to a ½ conduit connection or on a plate mounted on the back of the case. Three screws attach case to the mounting surface

12 Wiring the Gateway

13 Wiring the Remote

14 Using the Gateway and Remote(s) The Gateway is a highly integrated interface specially programmed to transmit and receive data to and from Remotes, and also act as a slave device via Modbus RTU RS485 to a controller. The primary purpose of the Gateway is to: communicate wireless operational information communicate/edit Gateway and remote operational parameters via MConfig or a programmable logic controller set Modbus RTU address and RF network address

15 The Remote is a highly integrated interface specially programmed to transmit end-device signals from site to the Gateway. With a printed antenna on the circuit board, the remote communicates to the Gateway via an RF link. The primary purpose of the Remote is to: provide near real-time data to Gateway battery operated device (low power) early reporting clear for start-up and class timer applications Set-Up Gateway and Remote NOTE: If initializing an existing system, skip to section 0 Gateway Factory Default Turn power on to unit. Press and hold the Program Button until the COP LED flashes at least ten (10) times and release. Factory Default Successful: o The COP LED will blink ten (10) times, verifying the factory default was successful

16 Factory Default Failed: o The COP LED will blink five (5) times, verifying the factory default was unsuccessful. Once succeeded, Turn off Gateway power. Wait at least 10 seconds. Turn Gateway power back on. The HEARTBEAT LED will blink in two (2) second intervals. Repeat the above steps when more than one Gateway is present in a single system. Remote Factory Default Press and hold the Activation Button (S301) until the Alert LED (DS302) flashes at least ten (10) times and release. Factory Default Succeeded: o The Alert LED (DS302) will blink ten (10) times, verifying the factory default was successful. Factory Default Failed: o The Alert LED (DS302) will blink five (5) times, verifying the factory default was un-successful. Repeat the above steps when more than one Remote is present in a single system. Initializing MConfig software The software templates provided in this software package will allow the user to change and manipulate the operation of the Gateway and Remotes. Each have factory settings to allow immediate operation. Care must be taken to assure the settings are changed according to the application requirements. Without verifying correct operational setpoints, the user could possibly leave the equipment unprotected. The MConfig software can be downloaded from our website at Follow installation instructions for the software before proceeding to the following steps

17 Step 1: Begin by activating the MConfig software. A blank screen will appear on the PC desktop as seen below. Step 2: Click on the File menu button on the upper left. A drop down box will appear. Click open

18 Step 3: A screen will appear as below. Click on (down arrow) on Files of Type. Select the M2_Setup Configuration (*.M2_Setup)

19 Step 4: Click on the default.m2_setup file. Name will appear in File name box. Then click the open button on the screen. A screen will appear providing the setup entry points for the Gateway and Remotes. Continue to next section for information regarding setup of Gateway and Remote(s)

20 Operational Setup Menu Below is the initial setup screen for setup of Gateway and Remote(s). Clicking the cursor on different rows allows the user to access read only information for the Gateway and Remote(s) and allows access to read/write registers for the Gateway and Remotes. Read only registers will be colored in white (see below). These are information registers for the user to provide information regarding the software and system analysis

21 Read/write register values will be colored in yellow (see below). These registers are user defined, but are provided with factory default settings as shown below. PC to Gateway Connection Install a USB to EIA-485 converter. Follow instructions provided with the converter hardware. Once device has been installed and configured on the PC, use the following guidelines to connect the PC to the Gateway. User can utilize another RS485 converter. Steps below will be inclusive when connecting to the M2 Wireless Gateway. Connect D+ on USB mini to Gateway RS-485-A terminal Connect D- on USB mini to Gateway RS-485-B terminal The user must establish a communication link between the PC and the Gateway. Follow the steps below to establish this link and begin defining the settings for the Gateway and Remote(s) for the control system operation

22 Step 1: Click on the Transfer menu, and click on Port Settings. During the installation of the USB device, user would have established the Com port necessary to use. Click on the port drop down box to choose the correct comm. port for the PC. Step 2: Target Slave number is 1, Baudrate is

23 Step 3: Click on Transfer menu, and click Upload to PC. A popup screen will show the progress of establishing communication between the PC and Gateway. Step 4: Upon establishing a communication link, the user will notice the Value fields will be populated and the Tx / Rx in the lower right corner of the screen will be alternating. The Gateway has an LED indication for communications which will be alternating TX (green) and Rx (red), confirming communication link

24 Gateway Network and RF Address After communication link is established, user must define the Modbus Node and RF addresses. The Modbus RTU Slave Node address defines the Modbus RTU RS485 for customer connection or controller connection to the Gateway. This is defaulted to Node address 1, Baud rate When using MConfig software, only use default baud rate. If this is changed, the user will lose communication link to the Gateway. Refer to section 0 to reestablish the communication link to continue. The RF address defines the Gateway communication address to the Remotes. It is imperative that the RF address is unique for each Gateway installed in each application and unique to any existing Gateways within 250 yards of each other. This is defaulted to 0, and must be set to a non-zero value between before any communication link from Gateway and Remote(s) can be established. Only odd numbers between 1 and 247, these are the only values that will be accepted. Using the MConfig configuration software, enable MODBUS writes by sending a value of 4660 to address (See #1 above)

25 Set the Modbus RTU RS485 network address by sending a unique value (1-247) to address (See #2 above) Set the RF Network address by sending a unique value (1-247) to address (See #3 above) Set the RF Priority Channel by sending a unique value (0-24) to address This is defaulted to zero, and must be changed when more than 1 Gateway is used in a single system, or when more than one Gateway exists within 250 yards of each other. (See #4 above) IMPORTANT! It is important to maintain a list of addresses at location so that two Gateways are not each programmed with the same address. If multiple Gateways are set to same address, remotes will be reporting to both (or more) Gateways and leave unit unprotected, or cause a shutdown of wrong unit. Gateway and Remote Learn Mode Operation Users can learn and activate up to 30 Remotes per Gateway in a system. Typical installation utilizes one (1) Gateway and seventeen (17) Remotes. Begin by placing the Gateway in a Learn Mode. This can be accomplished two ways

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27 Gateway Learn Method #1 User must enable Modbus writes using address (See #1 above) Then enter the remote number desired to learn (1 30). (See #2 above) This can be determined by the requirements per the application. If a remote has previously been learned to that number, a Modbus fail message will be given. The HEARTBEAT LED should begin flashing rapidly indicating that the Gateway has entered learn mode and is waiting for a remote to initiate the learn operation. (See Remote below) If the Gateway does not detect a remote initiating the learn operation within 30 seconds, it will time out and return to normal operation. Subsequent to timing out, the rapid flashing of the HEARTBEAT LED will end and return to flashing once every two seconds. Gateway Learn Method #2 Press and hold the PROGRAM button on the Gateway until the COP LED flashes two times then release. Use pinky finger or end of plastic pen to depress. DO NOT USE SHARP OBJECTS (knife, screw driver, etc.)

28 The COP LED should begin flashing rapidly indicating that the Gateway has entered learn mode and is waiting for a remote to initiate the learn operation. (See Remote below) If the Gateway does not detect a remote initiating the learn operation within 30 seconds, it will time out and return to normal operation. Subsequent to timing out, the rapid flashing of the HEARTBEAT LED will end and return to flashing once every two seconds. Remote Initiate Learn Operation at the Remote by pressing and holding the Activation Button (S301) on the Remote until LED (DS302) flashes two times, then release. Learn Operation Successful: o Remote: LED (DS301) will flash rapidly followed by LED (DS302) flashing two times to confirm success. o Gateway: The HEARTBEAT LED will stop flashing rapidly and the FET LED will illuminate that corresponds to the Remote we just added. If more than eight (8) remotes have been learned, the form c relay contact will be the status indicator for remotes

29 Learn Operation success can be confirmed via the MODBUS map by viewing the following MODBUS registers: o Register in the Gateway General Data indicates the Number of Remotes Added. This will increment each time a remote is added. o Register in the Gateway General Data indicates the Next Remote to Add value. This will increment each time a remote is added. Learn Operation Failed: o Remote: The Diagnostic LED (DS301) will stay on continuously while the Alert LED (DS302) flashes five (5) times to confirm failure. o Gateway: The COP LED may stop flashing as soon as the learn operation is initiated at the Remote indicating that the Learn Operation failed part way through the learn process. o Gateway: The COP LED may continue to flash indicating that the Gateway never received the initial communication packet from the Remote. Continue this process under section Gateway and Remote Mode Operation until all Remotes have been learned for the system. The responsibility is with the user to confirm each remote is learned in the correct location and is aligned with the operation requirements of the application and controller. **In the event the Gateway is replaced, or a Remote is removed from a system and being used in a new system, the Remote must be factory defaulted prior to the learn operation. See section 0 for the remote factory default process

30 Remote Configuration for Operation Users can now setup the functionality of the Remote. With the MConfig software, users are provided with the most vital information and values for operation of the remote(s) in a system. Each remote(s) will have a status menu. Below is a self-explanatory list common to each. Digital Remote(s) The sensor input for a single channel discrete remote can be configured for a Normally Open (NO) or Normally Closed (NC) sensor contact. A Digital Remote is a very low power device that utilizes sleep functionality to extend battery life. The Remote remains in a sleep state until one of the following conditions occur: A heartbeat needs to be sent to the Gateway. The switch that the Remote is connected to changes state

31 The status information above is unique to a digital remote. MODBUS address xxx22 or xxx72 defines the sensor type (1) and MODBUS address xxx23 or xxx73 defines how the sensor functions (2). When the remote is learned to system, the Remote tells the Gateway what type of sensor it is. This information is then defaulted into the system and displayed in the software. These settings are initially defaulted until the user changes them in the Remote Configuration menu below. Configuration: Using the MConfig configuration software, enable MODBUS writes by sending a value of 4660 to address in the Gateway configuration menu. Using the drop down box, select either NO Digital (if end-device is wired normally open) or NC Digital (if end-device is wired normally closed) in MODBUS register xxx38 or xxx88. Confirm that the value was written correctly in the Remote Status menu MODBUS register xxx22 or xxx72. Thermocouple Remote(s) The sensor input for a single channel thermocouple remote can be configured for a type J or type K thermocouple sensor input. A Thermocouple Remote is a very low power device that utilizes sleep functionality to extend battery life. The Remote remains in a sleep state until one of the following conditions occur: A heartbeat needs to be sent to the Gateway. The input needs to be read

32 The status information above is unique to a thermocouple remote. MODBUS address xxx22 or xxx72 defines the sensor type (1) and MODBUS address xxx23 or xxx73 defines the current temperature reading of the thermocouple input (2). MODBUS address xxx24 or xxx74 provides the thermocouple reading at the time of an event (3), and MODBUS address xxx25 or xxx75 is the CPU temperature at the time of an event (4). Values are locked in for a fault snapshot of the device and must be reset through the Gateway using the Gateway reset. (See section 0) When the remote is learned to system, the Remote tells the Gateway what type of sensor it is. This information is then defaulted into the system and displayed in the software. These settings are initially defaulted until the user changes them in the Remote Configuration menu below. Configuration: Using the MConfig configuration software, enable MODBUS writes by sending a value of 4660 to address in the Gateway configuration menu. Using the drop down box, select either K TC (if end-device is a type K thermocouple) or J TC (if end-device is a type J thermocouple) in MODBUS register xxx38 or xxx88. (1) Confirm that the value was written correctly in the Remote Status menu MODBUS register xxx22 or xxx72. TC Sample Delay, MODBUS address xxx39 or xxx89 (2) o This value determines the time interval the remote powers up and takes a temperature reading of the thermocouple. This reading monitors all settings listed below to determine if the remote needs to report to the Gateway prior to the scheduled heartbeat. Default is 15 seconds Min value is 3 seconds Max value is 60 seconds

33 NOTE: Reducing the sample rate below 15 seconds will reduce battery life; increasing above 15 seconds will increase battery life. TC Fault Hysterisis, MODBUS address xxx40 or xxx90 (3) o This value determines the Degree in temperature the reading must fall below the TC Upper Fault setpoint, or rise above the TC Lower Fault setpoint. Default is 5F Min value is 0F Max value is 10F TC Rate Increase Report, MODBUS address xxx41 or xxx91 (4) o This value determines the Degree in temperature the Remote will report an update on temperature rise. This early reporting feature allows for alarm banners and class lockout timers to exist while providing immediate feedback for permissives and timers in control system programming. Default is 5F Min value is 1F Max value is 100F TC Rate Decrease Report, MODBUS address xxx52 or xxx92 (5) o This value determines the Degree in temperature the Remote will report an update on temperature fall. This early reporting feature allows for alarm banners and class lockout timers to exist while providing immediate feedback for permissives and timers in control system programming. Default is 10F Min value is 1F Max value is 100F TC Upper Fault, MODBUS address xxx43 or xxx93 (6) o This value determines the Degree in temperature the Remote will report an event for a High Temperature Fault. Default is 195F NOTE: Changing the default value to 0 will disable this functionality Min value is 0F Max value is 2150F TC Lower Fault, MODBUS address xxx44 or xxx94 (7) o This value determines the Degree in temperature the Remote will report an event for a Low Temperature Fault. Default is 32F NOTE: Changing this default value to 0 will disable this functionality Min value is 0F Max value is 2150F

34 Removing a Remote from System After communication link is established per section PC to Gateway Connection, user can then utilize the MConfig software to remove a remote from the network. On the Gateway configuration, write a value of 4660 to MODBUS address to enable MODBUS writes. (See #1 above) Continue by writing the remote ID to be removed to MODBUS address twice. This will remove the remote from the network. (See #2 above) Continue removing any undesired Remotes. Confirm removal of the associated Remotes by reviewing the MODBUS register on the Gateway General Data. This value will decrease with each remote removed. Reset Heartbeat Counters (section 0) once removal is completed

35 General Information Battery Installation ONLY install or replace with approved batteries. One of two approved batteries can be used. o Lisun: ER14505 available from FW Murphy o Tadiran: TL-5903-S which is available from FW Murphy or 3 rd party suppliers such as Loosen case lid screws and open lid. Remove the PCB from the remote enclosure. Remove the battery installed on back side of PCB. Press the Activation Button (S301) for two seconds to drain any residual energy stored on the Remote. Insert the battery in the remote PCB assembly, while observing the battery polarity between the battery clips in the PCB assembly. LEDs will flash when correctly installed. Re-install PCB in enclosure. Press Activation Button to wake-up the remote and provide a heartbeat to the Gateway. Close lid and tighten screws

36 During a battery change, the Remote will maintain all settings established. Battery Life expectancy: Digital Remote One Battery o Normally Open Sensor 5 years o Normally Closed Sensor 3 years Thermocouple Remote Two batteries o Type J or K Input 4 years IMPORTANT: USE ONLY AUTHORIZED 3.6 VOLT LITHIUM BATTERIES. NEVER MIX OLD AND NEW BATTERIES. ALWAYS INSTALL THE BATTERY IN THE CORRECT ORIENTATION. DISPOSAL OF USED BATTERIES IN ACCORDANCE WITH LOCAL GOVERNING LAWS AND REGULATIONS Remote Battery Voltage The Remote battery voltage is monitored on address(es) xxx18(odd number remotes) and xxx68 (even number remotes). This address will provide the actual battery voltage of the remote. Example 36 would be 3.6 VDC. A Low Battery voltage counter will begin when the remote battery has reached 2.6 VDC. This is shown on address(es) xxx21(odd number remotes) and xxx71 (even number remotes). This counter will begin counting from 0 upwards. This counter will be utilized by the control system to initialize a low remote battery alarm. The user has seven full days to change battery before a system shutdown event will occur. After seven continuous days, the counter will auto fill the counter to max (65534). This reading will be utilized by the control system to flag a shutdown event. Once this event occurs, the battery in the remote must be changed to allow the unit to run safely and be properly protected. This counter cannot be manually manipulated. It can only be auto reset by replacing the battery and restoring adequate operational battery voltage to the remote

37 Heartbeat The Remote is programmed to send a heartbeat to the Gateway on a periodic basis which allows the Gateway to detect if a Remote goes offline due to RF communication issues or some other failure condition. During the heartbeat the following is transmitted to the Gateway. Remote battery voltage Remote board temperature Status of sensor If the Gateway flags a Remote with a missed heartbeat, then a value of will be stored in register xxx23/xxx73. Deep Sleep The M2Wireless system is designed to enter into a Deep Sleep mode when the Remote detects that the Gateway has been turned off for three (3) days to conserve battery life. Remotes will attempt to establish RF communications with the Gateway during the 3 days. When undetected for three days, Remotes will enter Deep Sleep automatically without operator intervention. Deep Sleep Operation While in Deep Sleep, the following behavior will be exhibited: Remotes will not respond to changes in the sensor inputs. Remotes will send heartbeats much less frequently in order to conserve battery life. Remotes will not respond to changes in sensor status until the RF communication link with the Gateway is re-established. IMPORTANT: The responsibility is with the user to protect the equipment and not allow the equipment to run until such time as the Gateway has indicated the system is completely operational. Wakeup from Deep Sleep Gateway is powered. Immediately after power up, the Form-C output on the Gateway will be connected between COM & NO. As Remote(s) status is reported, the individual bits in the Remote Status register will change state from 1 to 0. Each bit in this register maps directly to a Remote in the network

38 If all Remotes do not report in within 75 seconds, the FET LED s will illuminate and the FET s Outputs will activate (sink to ground). The user can review the Remote Status registers and to determine which Remote(s) did not report. Subsequent to Remote Status register and reading a value of zero, the Gateway Fault Reset (section 0), must be reset. IMPORTANT: The Remotes are sending a wakeup command less frequently than during normal heartbeat operation. It can take up to ten (10) minutes for the Gateway to register all Remotes in the network after coming out of Deep Sleep mode. The Gateway is not aware that the system has entered Deep Sleep mode. The Gateway will likely indicate a problem after the 75 second boot-up timeout. This occurs because the Remotes will not send an operational heartbeat in a Deep Sleep state. Reset Features On the Gateway Configuration, write a value of 4660 to MODBUS address to initialize MODBUS commands. Gateway Fault Reset Write a value of 161 to MODBUS address o Resets active faults in Gateway o Resets form C relay When the Gateway is reset, register xxx23/xxx73 in the Remote will maintain the same value it contained prior to reset. If a remote does not report in within the allowed boot timeout period (75 seconds) after the Gateway is reset, an event will occur as a missed heartbeat. A value of will be stored in register xxx23/xxx73. If the remote reports in within the boot timeout period, then registers xxx23/xxx73 in the Remote, will be updated based upon the data received from the remote. If the Gateway is reset after register xxx23/xxx73 contains a value of 10000, register xxx23/xxx73 will be reset to a value of zero and the Gateway will enter a waiting period until either the boot timeout period expires or a Remote reports in. At that time the value will be updated accordingly

39 Gateway Communications RS485 Port (Serial) Used for user connection Interface: RS485 configurable. Refer to the sequence of operation to determine the actual configuration. Baud rates are configurable 9600, 19200, 38400, No parity, 8 data bits, 1 stop bit. Protocol: Modbus RTU slave Connection: Two screw terminal connectors for RS485. These are identified as A and B. LED Indication: Two indicator LED s on Gateway. These are identified as RX (Red) and TX (Green). RS485 Port (Serial) Emergency Communication Connection Connection: This process will allow a user to set the Gateway to a known connection rate. This step should only be taken as a last resort as this will change all communication settings to the RS485 port. Any settings established with the Master device will need to be set again in the Gateway to re-establish the link. These steps will set the comm. port to 9600, N, 8, 1. Turn Power off to the Gateway Press and hold the Program Button on the Gateway Turn Power on to the Gateway Release the Program Button Cycle Power to the Gateway off then on again. The Gateway will now communicate at the given rate above. COP led will blink seven (7) times indicating success of emergency communication connection. Modbus RTU Protocol The M2 Wireless Gateway was programmed with the Modbus RTU protocol which is a system based on a master and slave relationship. The master initiates the queries or commands, and the slave responds to the query with a message or takes action based on the query. The Gateway is a Modbus slave device. In this case, the master is another Modbus client. There should never be two or more masters simultaneously. There can only be a single Modbus RTU master on a network

40 As with all numeric data defined within the Modbus RTU specification, the data is limited to accepting integers (whole numbers only, no decimals). This is important whenever a decimal point is defined in the main controller as it will be a forced or virtual decimal point. For example, for the controller to properly read with an implied decimal point of 1, the user would need to enter 1000 and 1000 would be stored in the appropriate Modbus register. The M2 Wireless Gateway has all data mapped into Modbus Holding Registers, formatted as assigned 16 bit integer data*. The Gateway responds to Modbus Function Code 03 for read holding registers limited to 100 registers per read. Valid register read is The Gateway responds to Function Code 06 for single holding register writes. These represent Read Holding Registers, Preset Single Register, and Preset Multiple Register Modbus functions. (*certain data points may be bitmapped data or signed data and will be specified on the Modbus RTU map). The Gateway(s) MODBUS map is identified from The Remote(s) MODBUS map is identified from Remote 1: MODBUS Registers Remote 3: MODBUS Registers Remote 5: MODBUS Registers Remote 7: MODBUS Registers Remote 9: MODBUS Registers Remote 10: MODBUS Registers Remote 13: MODBUS Registers Remote 15: MODBUS Registers Remote 17: MODBUS Registers Remote 19: MODBUS Registers Remote 21: MODBUS Registers Remote 23: MODBUS Registers Remote 25: MODBUS Registers Remote 27: Remote 2: MODBUS Registers Remote 4: MODBUS Registers Remote 6: MODBUS Registers Remote 8: MODBUS Registers Remote 10: MODBUS Registers Remote12: MODBUS Registers Remote 14: MODBUS Registers Remote 16: MODBUS Registers Remote 18: MODBUS Registers Remote 20: MODBUS Registers Remote 22: MODBUS Registers Remote 24: MODBUS Registers Remote 26: MODBUS Registers Remote28:

41 MODBUS Registers MODBUS Registers Remote 29: Remote 30: MODBUS Registers MODBUS Registers Modbus Register Map All data is signed 16 bit integer unless otherwise noted. GATEWAY MODBUS MAP Factory Use Description Read/W rite Range Data Units Gateway Firmware Revision R Factory RF Processor Firmware Revision R Factory Daughter Card Revision R Factory R Definitions Factory Use R Highest Remote ID R Number of Remote(s) R 0-30 The highest remote ID learned by the gateway. It is possible that this number may be higher than if remotes were removed from the system. The number of remotes active in the system Modbus Register Factory Use R System Voltage X10 R Factory Use Next Remote ID to be Added R Factory Use Remote Status 1 R R R DC Volts Typical Accuracy +/ 0.25v When adding remotes to the network, this is the remote ID of the next remote to be added. This 16 bit value contains a bitwise representation of remotes A value of 0 means the remote is functioning properly and a sensor event has not occurred. A value of

42 Modbus Register Description Remote Status 2 R Factory Use Read/W rite R Range Data Units Definitions means that a sensor #1 event occurred or a heartbeat was missed. See register This contains the data for remotes MODBUS Slave ID R/W MODBUS Slave ID RF Network Address R/W RF Priority Channel R/W Enable MODBUS Writes Passcode R/W 0 or 4660 A value of zero means that the network address has not been programmed. Remotes cannot be added if the value is zero. Each gateway within radio range must be programmed with a different network address. Defaulted to zero. Each gateway within radio range must be programmed with a different priority channel. Only addresses in odd numbers will be accepted. A value of zero means that MODBUS writes are disabled. MODBUS writes are enabled by writing a value of 4660 to this register after which this register will begin counting down. This countdown takes 10 minutes to return to zero after which MODBUS writes will be disabled. Once writes have been enabled, the countdown will be reset after each write to the gateway. 9600, 19200, Data rates supported by the RS 485 Data Rate R/W 38400, Gateway Remote ID to Delete R/W 1-30 Entering a valid remote ID

43 Modbus Register Description Read/W rite Factory Use R/W Factory Use R Range Learn (add) Remote ID R/W Factory Use Factory Use Gateway Resets Gateway Fault (165) R/W Factory Use REMOTE MODBUS MAP R R R 0 or 161 Data Units Definitions will remove a remote from the gateway s list of remotes. Entering a value of 0 will enable learn mode and add the remote to the next available location (register 40016). Entering a value from 1 30 will allow a remote to be added to the designation, provided that a remote is NOT learned in this location. Resetting statistical data in Gateway. Modbus Register xxx00, xxx50 Description Read/ Write Range Remote ID R 1-30 Data Units Definitions Defines the remotes address to the Gateway. xxx01, xxx51 xxx02 05, xxx52 55 xxx06, xxx56 Remote Taken? R 0-1 Factory Use R 0 = No 1 = Yes Firmware Revision R Factory Use Indication that a remote is currently learned at the identified location

44 Modbus Register xxx07 10, xxx57 60 xxx11, xxx61 xxx23, xxx73 xxx24, xxx74 xxx12, xxx62 xxx13 16, xxx63 66 xxx17, xxx67 xxx18, xxx68 xxx19 20, xxx69 70 xxx21, xxx71 xxx22, xxx72 xxx25, xxx75 xxx26 31, xxx76 81 xxx32, xxx82 Description Factory Use Read/ Write R Range Data Units RSSI Signal Strength From Gateway R dbm RSSI Signal Strength From Remote R dbm Factory Use CPU Temperature Battery Voltage Factory Use Battery Voltage Counter R R R R R -40 to to Sensor Type R 1 or 10 Sensor Info TC Event Temperature TC Event Cold Junction Temperature Factory Use R R R 0 or 16 1 or to to to +185 Missed Heartbeat Before Alert R/W 1-5 R Deg. F X10 Volts DC Deg. F Deg. F Definitions 63 = strongest 115 = weakest 63 = strongest 115 = weakest Ambient temperature of the remote electronics. 25 = 2.5v 40 = 4.0v Low battery voltage alarm / shutdown 1 = Discrete 10 = Thermocouple 0 = DI, NO, No Event 16 = DI, NO, Event 1 = DI, NC, No Event 17 = DI, NC, Event 200 to 2500 = TC Temp = Missed Heartbeat, Event Thermocouple temperature when a trip point was passed. Cold junction temp when a TC trip point was passed. Number of heartbeats that must be consecutively missed before a missed heartbeat is flagged by the

45 Modbus Register xxx39, xxx89 xxx40, xxx90 xxx41, xxx91 xxx42, xxx92 xxx43, xxx93 xxx44, xxx94 xxx33 37, xxx83 87 xxx38, xxx88 xxx45 49, xxx95 99 Description Factory Use Read/ Write R Range Sensor Type R/W 0 or 1 Data Units TC Sample Delay R/W 3-60 Seconds TC Fault Hysteresis R/W 0-10 Degrees TC Rate Increase Report R/W Degrees TC Rate Decrease Report R/W Degrees TC Upper Fault R/W Degrees TC Lower Fault R/W Degrees Factory Use R Definitions gateway. 0 = NO or Type K 1 = NC or Type J Number of seconds between thermocouple samples. Number of degrees that the TC temp must return inside the valid operating temp before the fault is cleared. Number of degrees that the TC temp must increase before the remote sends an updated TC temp to the gateway. Number of degrees that the TC temp must decrease before the remote sends an updated TC temp to the gateway. Max valid TC temp. Rising above this will cause a fault condition. Set to 0 will disable fault. Min valid TC temp. Falling below this will cause a fault condition. Set to 0 will disable fault

46 Replacement Parts and Assemblies M2 Wireless Antenna Kit M2 Wireless Remote Antenna Kit M2 Wireless PC Interface Kit M2 Wireless Remote Battery ( ) Replacement antenna and bulkhead ( ) External remote mounted antenna bracket and cable ( ) USB to RS485 converter and cable ( ) Replacement Lithium 3.6 VDC, AA battery Accessories M2 Wireless Configuration Tool Software The MConfig software generates and modifies the properties of the system specific to the hardware connected to the controller, defined set points, timers, and faults for the M2 Wireless system. Some fault setpoints may be maintained in the main controller of the system based on the requirements for the application. The software includes file transfer utilities for configuration upgrades. MConfig software free download

47 Appendices Gateway LED Description Heartbeat LED No Remotes added to the network, properly functioning: o The LED will blink slowly. It will change state every 2 seconds. Remotes added to the network, properly functioning: o The LED will turn on for ¼ second followed by an off time of 2 seconds. Learn Mode: o The LED will blink at a rate of ¾ second this is a fast blink rate. RF system did not initialize o The LED will blink every ¼ second this is a very rapid blink rate indicating an error condition. COP LED Process indication for the Program button when entering learn mode or performing a factory default. Remote LED Description DS301 LED Learn Mode Success: o The LED will flash rapidly. Learn Mode Failure: o The LED will turn on. Heartbeat: o The LED will flash once every minute. DS302 LED Learn Mode Success: o The LED will flash twice. Learn Mode Failure: o The LED will flash 5 times

48 FCC/IC Compliance, Warnings, & Battery information FCC/IC Compliance This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. The FCC Class B limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: o Reorient or relocate the receiving antenna. o Increase the separation between the equipment and receiver. o Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. o Consult the point of purchase or service representative for additional suggestions. The manufacturer is not responsible for any radio or television interference caused by using other than recommended cables or by unauthorized changes or modifications to this equipment. Unauthorized changes or modifications could void the user's authority to operate this equipment. This equipment must be installed by qualified professionals or contractors in accordance with FCC Part , Antenna Requirements. Do not use any antenna other than the one provided for the unit

49 Warnings FW Murphy designs, manufactures, and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, users must properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions must be adhered to and integrated into your safety program when installing, using, and maintaining M2 Wireless products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation. Read all instructions prior to installing, operating, and servicing the product. Save this Instruction Manual for future reference. If you do not understand any of the instructions, contact your Murphy representative for clarification. Follow all warnings, cautions, and instructions marked on and supplied with the product. Inform and educate your personnel in the proper installation, operation, and maintenance of the product. Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes. Connect all products to the proper electrical and pressure sources. To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product. When replacement parts are required, ensure that qualified people use replacement parts specified by FW Murphy. Unauthorized parts and procedures can affect the product s performance and place the safe operation of your process at risk. Look a-like substitutions may result in fire, electrical hazards, or improper operation. Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury. RF Exposure To comply with FCC RF exposure requirements for mobile transmitting devices, this equipment should only be used or installed at locations where there is normally at least a 12 inch separation between the antenna and all persons. NOTE: The Remote contains an internal antenna while the Gateway uses an external antenna. Do not co-locate and operate in conjunction with any other antenna, antenna cable, or transmitter. Changes or modifications not expressly approved by Recognition Source could void the user s authority to operate this equipment. Do not install a Remote closer than 1 foot (12 inches) to the Gateway antenna. -Post installation, user must verify operation of entire control system. Wired and wireless connetion devices

50 Battery Information Primary lithium batteries are regulated in transportation by the U. S. Department of Transportation, and are also covered by IATA (International Air Transport Association), ICAO (International Civil Aviation Organization), and ARD (European Ground Transportation of Dangerous Goods). It is the responsibility of the shipper to ensure compliance with these or any other local requirements. Please consult current regulations and requirements before shipping. The batteries should not be opened, destroyed or incinerated, since they may leak or rupture and release to the environment the ingredients that they normally contain in the hermetically sealed container. HANDLING- Do not short circuit terminals, or expose to temperatures above the temperature rating of the battery, over charge the battery, forced over-discharge (voltage below 0.0V), throw to fire. Do not crush or puncture the battery, or immerse in liquids. STORAGE- is preferably done in cool (below 30ºC), dry and ventilated area, which is subject to little temperature change. Do not place the battery near heating equipment, nor expose to direct sunlight for long periods. Elevated temperatures can result in shortened battery life and degrade performance. Keep batteries in original packaging until use and do not jumble them. Do not store batteries in high humidity environment for long periods. OTHER- these are NOT rechargeable batteries and should not be charged. Applying pressure and deforming the battery may lead to disassembly followed by eye, skin and throat irritation. Follow manufacturer recommendations regarding maximum recommended current and operating temperature range. SHIPPING - The unit was shipped without the battery(ies) installed. Please remove the battery(ies) from the unit prior to shipping. DISPOSAL CONSIDERATIONS o Dispose in accordance with the applicable regulations in country and state. o Disposal should be performed by permitted, professional disposal firms knowledgeable in Federal, State or Local requirements of hazardous waste treatment and hazardous waste transportation. o Incineration should never be performed by battery users. Incineration is done by trained professionals in an authorized facility with proper gas and fume treatment. o Battery recycling should only be done in an authorized facility. o See manufacturing data for additional information and warnings. o User must check and use local laws and regulations for Lithium Battery Disposal/Recycling

51 MODBUS Register Access Gateway: MODBUS Registers See the MODBUS map overview for more information. Remote: Each Remote is provided with a dedicated range of 50 (fifty) MODBUS registers as outlined in the table below. Access to a remote is made by adding the MODBUS register you wish to access to the base address of the remote in question. For instance, the firmware revision is located at register 6 into each remote s address space. Therefore, reading the firmware revision requires a read from register: Remote #1 would read from 206 ( ). Remote #6 would read from 456 ( ). Writing to a Remote operates the same way. For instance, Configuration Register 0 (CONFIG_0) is located at register 38. Writing to CONFIG_0 requires writing to: Remote #1 would write to 238 ( ). Remote #6 would write to 488 ( ). Remote 1: MODBUS Registers Remote 3: MODBUS Registers Remote 5: MODBUS Registers Remote 7: MODBUS Registers Remote 9: MODBUS Registers Remote 10: MODBUS Registers Remote 13: MODBUS Registers Remote 15: MODBUS Registers Remote 2: MODBUS Registers Remote 4: MODBUS Registers Remote 6: MODBUS Registers Remote 8: MODBUS Registers Remote 10: MODBUS Registers Remote12: MODBUS Registers Remote 14: MODBUS Registers

52 CALL MURCAL TO PLACE YOUR ORDER MurCal P:(661) F:(661)