How can I Implement a cost-effective energy monitoring system for small to medium buildings using Com'X 510? Tested Validated Documented Architecture Develop your project
Important Information Notice People responsible for the application, implementation and use of this document must make sure that all necessary design considerations have been taken into account and that all laws, safety and performance requirements, regulations, codes, and applicable standards have been obeyed to their full extent. Schneider Electric provides the resources specified in this document. These resources can be used to minimize engineering efforts, but the use, integration, configuration, and validation of the system is the user s sole responsibility. Said user must ensure the safety of the system as a whole, including the resources provided by Schneider Electric through procedures that the user deems appropriate. This document is not comprehensive for any systems using the given architecture and does not absolve users of their duty to uphold the safety requirements for the equipment used in their systems, or compliance with both national or international safety laws and regulations. Readers are considered to already know how to use the products described in this document. This document does not replace any specific product documentation. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. The addition of this symbol to a "Danger" or "Warning" safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. 3
Before You Begin NOTICE NOTICE is used to address practices not related to physical injury. Note: Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. A qualified person is one who has skills and knowledge related to the construction, operation and installation of electrical equipment, and has received safety training to recognize and avoid the hazards involved. This automation equipment and related software is used to control a variety of industrial processes. The type or model of automation equipment suitable for each application will vary depending on factors such as the control function required, degree of protection required, production methods, unusual conditions and government regulations etc. In some applications more than one processor may be required when backup redundancy is needed. Only the user can be aware of all the conditions and factors present during setup, operation and maintenance of the solution. Therefore only the user can determine the automation equipment and the related safeties and interlocks which can be properly used. When selecting automation and control equipment and related software for a particular application, the user should refer to the applicable local and national standards and regulations. The National Safety Council s Accident Prevention Manual also provides much useful information. Ensure that appropriate safeties and mechanical/electrical interlocks protection have been installed and are operational before placing the equipment into service. All mechanical/electrical interlocks and safeties protection must be coordinated with the related automation equipment and software programming. Note: Coordination of safeties and mechanical/electrical interlocks protection is outside the scope of this document. START UP AND TEST Before using electrical control and automation equipment for regular operation after installation, the system should be given a start up test by qualified personnel to verify the correct operation of the equipment. It is important that arrangements for such a check be made and that enough time is allowed to perform complete and satisfactory testing. WARNING EQUIPMENT OPERATION HAZARD Follow all start up tests as recommended in the equipment documentation. Store all equipment documentation for future reference. Software testing must be done in both simulated and real environments. Failure to follow these instructions can cause death, serious injury or equipment damage. Verify that the completed system is free from all short circuits and grounds, except those grounds installed according to local regulations (according to the National Electrical Code in the USA, for example). If high-potential voltage testing is necessary, follow recommendations in the equipment documentation to prevent accidental equipment damage. 4
Before energizing equipment: Remove tools, meters, and debris from equipment Close the equipment enclosure door Remove ground from incoming power lines Perform all start-up tests recommended by the manufacturer 5
OPERATION AND ADJUSTMENTS INTENTION The following precautions are from NEMA Standards Publication ICS 7.1-1995 (English version prevails): Regardless of the care exercised in the design and manufacture of equipment or in the selection and rating of components; there are hazards that can be encountered if such equipment is improperly operated. It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe operation. Always use the manufacturer s instructions as a guide for functional adjustments. Personnel who have access to these adjustments should be familiar with the equipment manufacturer s instructions and the machinery used with the electrical equipment. Only those operational adjustments actually required by the operator should be accessible to the operator. Access to other controls should be restricted to prevent unauthorized changes in operating characteristics. WARNING UNEXPECTED EQUIPMENT OPERATION Only use software tools approved by Schneider Electric for use with this equipment. Update your application program every time you change the physical hardware configuration. Failure to follow these instructions can cause death, serious injury or equipment damage. This document is intended to provide a quick introduction to the described system. It is not intended to replace any specific product documentation, nor any of your own design documentation. On the contrary, it offers information additional to the product documentation on installation, configuration and implementing the system. The architecture described in this document is not a specific product in the normal commercial sense. It describes an example of how Schneider Electric and third-party components may be integrated to fulfill an industrial application. A detailed functional description or the specifications for a specific user application is not part of this document. Nevertheless, the document outlines some typical applications where the system might be implemented. The architecture described in this document has been fully tested in our laboratories using all the specific references you will find in the component list near the end of this document. Of course, your specific application requirements may be different and will require additional and/or different components. In this case, you will have to adapt the information provided in this document to your particular needs. To do so, you will need to consult the specific product documentation of the components that you are substituting in this architecture. Pay particular attention in conforming to any safety information, different electrical requirements and normative standards that would apply to your adaptation. It should be noted that there are some major components in the architecture described in this document that cannot be substituted without completely invalidating the architecture, descriptions, instructions, wiring diagrams and compatibility between the various software and hardware components specified herein. You must be aware of the consequences of component 6
substitution in the architecture described in this document as substitutions may impair the compatibility and interoperability of software and hardware. CAUTION EQUIPMENT INCOMPATIBILITY OR INOPERABLE EQUIPMENT Read and thoroughly understand all hardware and software documentation before attempting any component substitutions. Failure to follow these instructions can result in injury or equipment damage. 7
This document is intended to describe the network architecture for a cost-effective energy monitoring system for small to medium facilities, using the Com'X 510 digital and analog inputs and meter data. DANGER HAZARD OF ELECTRIC SHOCK, BURN OR EXPLOSION Only qualified personnel familiar with low and medium voltage equipment are to perform work described in this set of instructions. Workers must understand the hazards involved in working with or near low and medium voltage circuits. Perform such work only after reading and understanding all of the instructions contained in this bulletin. Turn off all power before working on or inside equipment. Use a properly rated voltage sensing device to confirm that the power is off. Before performing visual inspections, tests, or maintenance on the equipment, disconnect all sources of electric power. Assume that all circuits are live until they have been completely de-energized, tested, grounded, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of back feeding. Handle this equipment carefully and install, operate, and maintain it correctly in order for it to function properly. Neglecting fundamental installation and maintenance requirements may lead to personal injury, as well as damage to electrical equipment or other property. Beware of potential hazards, wear personal protective equipment and take adequate safety precautions. Do not make any modifications to the equipment or operate the system with the interlocks removed. Contact your local field sales representative for additional instruction if the equipment does not function as described in this manual. Carefully inspect your work area and remove any tools and objects left inside the equipment. Replace all devices, doors and covers before turning on power to this equipment. All instructions in this manual are written with the assumption that the customer has taken these measures before performing maintenance or testing. Failure to follow these instructions will result in death or serious injury. 8
Table of Contents 1. Introduction 10 1.1. Purpose 10 1.2. Customer Challenges 10 1.3. Prerequisites 10 1.4. About this Document 11 2. Selection 13 2.1. Selected Architecture 13 3. Design and Validation 15 3.1. Network Architecture 15 3.2. Verification Results 16 3.3. Validation Results 16 4. Configuration and Implementation 19 4.1. Wiring 19 4.2. Com'X 510 and EGX100 Serial Port Configuration 22 4.3. Communication Settings for Serial Devices 22 4.4. Device Setup in the Com'X 510 22 5. Operation 25 5.1. Viewing Data for Serial or Ethernet Devices 25 5.2. Viewing Data for Devices through Digital or Analog Inputs 25 6. Maintenance 26 6.1. Com'X 510 Maintenance 26 6.2. Device Maintenance 26 7. Conclusion 27 8. Appendix 28 8.1. Bill of material and software 28 8.2. Reference documents 28 9
1 - Introduction 1. Introduction 1.1. Purpose The purpose of this document is to provide tested, validated, and documented instructions for deploying the Com'X 510 Energy Server as an alternative to an energy monitoring software solution. The target application is for small to medium buildings, including: Small schools, clinics, shops, retail convenience or chain stores Group housing, apartment blocks and high-end residential Small to medium hotels Colleges General offices and public buildings This document describes the network architecture for an entry-level energy monitoring solution for these types of facilities using the Com'X 510 inputs combined with meter data. The architecture supports multiple connection types such as: Devices connected to the Com X 510 inputs Serial connections Ethernet remote connections When properly configured, the Com'X 510 can display logged and real-time data through web pages on the Com'X 510, as well as through data log publication. 1.2. Customer Challenges This document is intended to meet the following challenges for customers: No direct and detailed view of energy usage before receiving utility bills. High cost of deploying an energy monitoring system for system integrators. Complex setup of an energy monitoring system involving hardware and software components. 1.3. Prerequisites 1.3.1. System Prerequisites The devices below were used in the validation of the TVD. However, you can substitute devices to include: energy meters, high-end meters, medium range meters, circuit breakers, and WAGES devices. Schneider Electric recommends limiting the Com'X 510 to 32 serial loads and 64 total devices. 10
1 - Introduction Software/Firmware Supported Com'X 510, firmware v1.0.12 EGX100, firmware v3.0 EM6400, firmware v3.05.03 ION 7330 PM3250, firmware v1.0.901 PM870, firmware v12.200 OS PM5350, firmware v3.0.4 OS PM1200, firmware v3.05.03 Powerpact A, firmware v2.2.7 Notes on version support No device substitution supported. Substitute any low-end Modbus gateway with access to remote devices. Substitute any electrical Modbus meter. Specific firmware version was not validated. Substitute any high-end meter Substitute any medium range power meter. Substitute any circuit breaker, for example a Masterpact. IFM, firmware 1.1.1 -- SHO 100 Humidity Sensor STO 300 Temperature sensor Substitute any 0-10V or 4-20mA device. Substitute any 0-10V or 4-20mA device. 1.3.2. Competencies To use the Com'X 510 for energy monitoring as specified, you must be familiar with: A standard web browser. Functionality of the selected meters, breakers, and WAGES devices. 1.4. About this Document This document is structured as follows: The Introduction gives an overview of the reason for the architecture and the prerequisites necessary to achieve it. The Selection section explains when you would choose this as a solution for a customer need. The Design and Validation section explains the architecture and design of the deliverables as well as how to verify proper function, and includes any information the lab has collected regarding the performance and limits of the architecture. The Configuration and Implementation section describes how to set up the architecture. The Conclusion attempts to summarize the key aspects you should follow to achieve the architecture. Read this section if you want to quickly assess your capability to understand and follow the procedures in the document. The Appendix provides reference materials and additional instructions for advanced configurations. 11
1 - Introduction Target Audience Execution Center Designers Sales/Bid Responders Business Development Application Engineers, Project Staff Technical Support Introduction Selection Design & Validation Document Section Configuration & Implementation Operation Maintenance Conclusion 12
2 - Selection 2. Selection This TVD network architecture describes the network architecture for a switched mode connection with Com'X 510 and EGX100 gateways connected to the Ethernet network via an upstream switch. The EGX100 was chosen as a passthrough gateway for this solution because it allows remote access to connected devices. This architecture is appropriate for customers who: cannot connect to a hosted energy monitoring service for network isolation reasons. need a entry-level option for energy monitoring, without the high costs of software licenses, specialized hardware (such as server computers), support, and training. 2.1. Selected Architecture WAGES devices are connected both locally on the Com'X 510 inputs and serial port and remotely through the EGX100 serial port. The Com'X510 communicates with the EGX100 gateway through Ethernet. Energy consumption information can then be viewed for all devices in a web browser with the Com'X 510 Monitoring features and/or in an external application using the Publication feature. The devices for the selected architecture are: Electrical Modbus meters EM6400 ION 7330 PM3250, PM800 Series, PM5350, PM1200 Circuit breakers Powerpact A Pulse devices Gateway PowerLogic EGX 100 Ethernet Gateway 0-10V or 4-20mA devices SHO 100 Humidity Sensor STO 300 Temperature sensor This system is monitoring a single-phase 110 V AC voltage source (see Design for an electrical power diagram). The drawing below describes the network architecture: 13
2 - Selection 14
3 - Design and Validation 3. Design and Validation Your actual performance will vary, depending on environment, duty cycle, load type, and other factors. 3.1. Network Architecture The network architecture supports a switched mode connection with Com'X 510 and EGX100 gateways connected to the Ethernet network via an upstream switch. Three of the meters (PM3250, EM1200 and EM6400) are serially connected to the EGX100 and the rest of the meters are serially connected to the Com'X 510. Pulse meters and sensors are connected to the Com'X 510 digital and analog inputs. Below is the lab panel layout for the architecture: 15
3 - Design and Validation A TWIDO programmable logic controller was configured with TwidoSuite software v2.20 to generate two continuous pulse outputs at an interval of 100ms. These pulses are used as inputs to a water or gas custom pulse devices. These devices are based on custom models in the Com'X 510 Custom Library and are used to simulate water and gas flow rates. Com'X 510 product testing confirms that these types of meters are supported by Com'X 510. 3.2. Verification Results Commissioning the Com'X 510 for this architecture was completed in 23 minutes and 12 seconds, and includes the following configuration steps: 1. Upgrade firmware over USB (to v1.0.10). 2. Log in to the Com'X. 3. Verify the firmware is installed. 4. Set up publication. 5. Set up date/time. 6. Set up logging interval. 7. Configure Site information. 8. Add all devices (8) 9. Turn on publishing. 10. Turn on data logging. The serial devices were added using the Device Discovery feature. Custom models were created for the gas and water meters and humidity and temperature sensors, and this is included in the commissioning time. 3.3. Validation Results The Com'X 510 has built-in web pages for viewing real-time data and data stored on the box. The Monitoring tab provides real-time and historical chart views for devices through the gateway, and the Measurements Table provides views for equipment connected downstream. You can also refer to published data logs for each device for further data analysis. See Operation for details on using Com'X 510 energy monitoring features. 16
3 - Design and Validation The Year over Year Energy dashboard allows you to view total usage for each month: You can then view detailed monthly usage with Historical Trending, which displays all data points logged within the selected date range. For each topic, you can view up to four devices on the same graph. Below displays the value for each logging interval for the month of July: 17
3 - Design and Validation You can also view the current status of your system to look for unexpected usage, such as high after-hours energy usage. Real Time Data allows you to view detailed information for a single device or a summary of multiple devices: Single Device View for PM3250 Summary Device View: Power for PM3250 and PM870s 18
4 - Configuration & Implementation 4. Configuration and Implementation Refer to the documentation for each device in the selected architecture for complete instructions and safety information (see 8.2 Reference documents). Below are the configuration steps for the selected architecture. Processes may vary based on device substitutions. 4.1. Wiring Below is the 2-wire RS485 wiring diagram for connecting serial devices to the Com'X 510 and EGX100. Note that the selected device labels use a variety of symbols for RS485 wiring, and this drawing highlights examples of these differences. 4.1.1. Gateways Below is the wiring diagram for the EGX100 serial port and power supply. Refer to the EGX100 Installation Guide for complete instructions (see 8.2 Reference documents). 19
4 - Configuration & Implementation 4.1.2. Micrologic and Powerpact Breakers Powerpact Wiring Diagram to Com X510 through the IFM: 4.1.3. Analog Sensors SHO100 humidity sensor wiring diagram to the Com X510 in 0 10 V configuration: 20
4 - Configuration & Implementation SHO100 humidity sensor wiring diagram to the Com X510 in 4 20 ma configuration: STO300 Temperature Sensors 4 20 ma Wiring Diagram 4.1.4. Pulse Devices TWD LMDA 20RT modular controller base was used to generate digital pulses, simulating digital gas and water meter inputs. Refer to the installation guide for your specific pulse meter(s) for wiring instructions (see 8.2 Reference documents). 21
4.2. Com'X 510 and EGX100 Serial Port Configuration 4 - Configuration & Implementation Serial communication settings for all devices on the serial bus must be the same and match the gateway settings. For example, values for EGX100 and Com'X510 for this TVDA are: Physical interface: RS485 2-Wire Number of stop bits: 1 Baud rate: 19200 Parity: None Response Timeout: 200 ms for EGX 100 and 1000 ms for Com'X 510 4.3. Communication Settings for Serial Devices Serial communication settings for all devices on the serial bus must be the same and match the gateway settings. Values for this TVDA are: Baud rate: 19200 Parity: None 4.3.1. Configuring the EM6400 You can use the meter display to configure Baud rate and parity for the EM6400. 4.3.2. Configuring the ION7330 Serial communications are available on COM1, and COM2. To enable communications through the meter serial ports, configure the applicable communications module. The Protocol, Tran delay, Baud rate, and unit ID setup registers must properly match your system and can be set through the meter front panel or ION software. 4.3.3. Configuring the PM1200 You can use the meter display to configure Baud rate and parity for the PM1200. 4.3.4. Configuring Micrologic and Powerpact Breakers You can communicate with a Micrologic or Powerpact circuit breaker through the IFM communication module. Use the two coding wheels on IFM front panel to set the Modbus address. The IFM module automatically detects the Baud rate and parity of the connected breaker when it is connected to the Modbus serial port. 4.4. Device Setup in the Com'X 510 To view energy consumption data on the Com'X 510, devices must be added to the Com'X 510 hierarchy and configured for logging. 22
4 - Configuration & Implementation 4.4.1. Adding Devices To add remote and local serial devices and digital inputs in the Com'X 510 Device Settings: Use Device Discovery to discover the devices that are locally connected to the Modbus serial port and the downstream EGX100. Create or import the provided custom models for pulse meters. Add an input to the Com'X 510 under Digital and Analog Inputs. 23
4 - Configuration & Implementation After the devices are added in the Com'X 510, the Device Settings tab displays the hierarchy: 4.4.2. Configuring Devices for Logging Each device logs certain measurements by default. You can customize the measurements to be logged and published for each device from Device Settings. Then, you can start data logging in the Commissioning main tab. The Com'X 510 User Manual contains a quick start guide for setting up data logging (see 8.2 Reference documents). 4.4.3. Publishing.csv Data Logs For devices that are not viewable in the Monitoring tab, you may want to publish data logs for analysis outside the Com'X 510. You can set up the device log publication type (.csv) and frequency in Settings > General Settings > Publication. Then, start publication from the Commissioning main tab. 24
5 Operation 5. Operation The Com'X 510 provides views of real-time data along with historical data log trends and dashboards. After the devices are configured for logging, you can view data on the Monitoring and/or Measurements Table tab. Alternatively, you can view data logs for all devices in the published.csv files. NOTE: Power outages or device reboot may cause small gaps in data. 5.1. Viewing Data for Serial or Ethernet Devices For most devices connected to the Com'X 510 or EGX100 serial port, the Monitoring tab displays: Real Time Data for single or multiple devices. Energy Dashboards for comparing usage on a device time over time. Historical Trending for comparing usage on multiple devices for a topic or multiple topics for a single device. See the Com'X 510 User Manual for a list of devices that are not viewable in the Monitoring tab (see 8.2 Reference documents). 5.2. Viewing Data for Devices through Digital or Analog Inputs Data from devices on the Com'X 510 digital and analog inputs are not available in the Monitoring tab. To view real time data for these devices, click the Measurements Table main tab, then scroll to the device. You can also refer to the published.csv data logs for historical data. 25
6 Maintenance 6. Maintenance 6.1. Com'X 510 Maintenance Update the Com'X firmware to the latest version as it becomes available, and clear browser cache after each firmware upgrade. You can find the latest firmware version in the Shopping Kiosk, the Solutions Expert Community, or the Com'X range page at www.schneider-electric.com. Always back up the configuration before upgrading the Com'X 510 or after making any changes to the configuration. 6.2. Device Maintenance See the documentation for each connected WAGES device for maintenance related to the device's hardware or firmware (8.2 Reference documents). If you need to replace a connected device, you can also replace it within the Com'X 510 device tree view with the Replace Device feature. This allows you to update hardware with the same or similar device type while maintaining continuity in data reporting. Before replacing or removing a device, you must stop data logging and publishing in the Commissioning tab. After replacement, restart data logging and publishing. 26
7 - Conclusion 7. Conclusion This tested, validated, and documented architecture allows you to deploy the Com'X 510 energy server as an alternative to an energy monitoring software solution for small to medium buildings, including: Small schools, clinics, shops, retail convenience or chain stores Group housing, apartment blocks and high-end residential Small to medium hotels Colleges General offices and public buildings These instructions describe how to implement an architecture that supports devices connected to the Com X 510 inputs and serial port as well as Ethernet remote connections through the EGX100. Logged and real-time data can be viewed through Com'X 510 web pages and published data logs, providing a timely and detailed view of energy consumption for a facility, all at a lower cost to the end customer. 27
8 - Appendix 8. Appendix 8.1. Bill of material and software Description The following table summarizes all of the selected hardware. As noted in the Introduction, some of these devices can be substituted for devices with similar functionality: Reference Firmware or software version Function Com'X 510 EBX510 1.0.12 Energy server used for energy monitoring EGX100 Modbus Gateway EGX100SD 3.020 Passthrough gateway for providing access to remote devices EM6400 EM6400IE DM 1.0RS 3.05.03 Modbus electrical meter ION 7330 S7330A0B0B0E0A0A N/A Modbus electrical meter PM3250 METSEPM3250 v1.0.901 Modbus electrical meter PM870 PM870 v12.200 OS Modbus electrical meter PM5350 METSEPM5350 v3.0.4 OS Modbus electrical meter PM1200 METSEPM1200 3.05.03 Modbus electrical meter. Firmware is not upgradable. PowerPact A HDL36030U54XEH V2.2.7 Circuit breaker IFM TRV00210 v1.1.1 Modbus interface module for communicating with PowerPact circuit breaker SHO 100 SHO100 N/A Humidity sensor STO 300 STO300 N/A Temperature sensor Web browser PC or mobile device Windows XP, Vista, or Windows 7 Allows viewing of logged and real time data for energy monitoring 8.2. Reference documents The following table is a list of documents you might want to refer to when more details are needed. They are available at www.schneider-electric.com or in the Schneider Electric Shopping Kiosk. Enter the document reference in the search box. Document title Reference Com'X 200, 210, 510 Instruction Sheet 253534170 Com'X 510 User Manual Com'X 200 Metering and Data Acquisition System Installation Guide DOCA0098EN DOCA0035EN PowerLogic Ethernet Gateway EGX100 Installation Guide 63230-319-200 PowerLogic Ethernet Gateway EGX100 User Guide 63230-319-204 28
8 - Appendix Document title Breaker Status Control Module (BSCM) with NSX Cord for PowerPact H-, J-, and L-Frame Circuit Breakers Instruction Bulletin SHO100 Outdoor Humidity Sensor Instructions STO 300 Temperature Sensor Instructions Twido PLC TWDLMDA20DRT Programmable Controllers Hardware Guide TwidoSuite V2.3 Programming Guide EM6400 Series Power Meter Quick Start Guide EM6400 User Manual Reference S1A80374 0FL4201001 0FL4183001 35011387 35011386K01000 CTD7302 NHA12535 ION 7330 Installation Guide 70002-0198 ION 7330 User Manual 70002-0162 PM3250/3255 Instruction Sheet PM3200 Series User Manual S1B46607 DOCA0006EN PM800 Series Power Meter Installation Guide 63230-500-282 PM800 Series Power Meter Quick Reference Guide PowerLogic Series 800 Power Meter PM810, PM820, PM850, & PM870 User Guide 3000DB0808 63230-500-225 PowerLogic PM5350 Installation Guide 63230-401-202 PowerLogic PM5350 User Manual 63230-401-203 PowerLogic PM1000 Series Quick Start Guide PowerLogic PM1000 Series Power Meters User Manual PLSED309038EN PLSED309039EN 8.3. Document Version Version Changes Author 1.0 Original version Katie Cullen 29
8 - Appendix 30
PowerLogic, Twido, and TwidoSuite are trademarks or registered trademarks of Schneider Electric. Other trademarks used herein are the property of their respective owners. Schneider Electric Industries SAS Head Office 35, rue Joseph Monier 92506 Rueil-Malmaison Cedex FRANCE Due to evolution of standards and equipment, characteristics indicated in texts and images in this document are binding only after confirmation by our departments. www.schneider-electric.com Version 1.0 04/2015