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Electro-Sensors HazardPRO Series Installation Manual

System manager
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Summary of Contents for Electro-Sensors HazardPRO Series

  • Page 2 Operation Manual, System Wiring Information, Modbus Options, and optional mounting in- formation. Additional information regarding HazardPRO sensors and nodes can be found in the Hazard- PRO node and sensor Installation document Volume 2. For any additional questions please contact our Technical Department via Tech@electro-sensors.com or by telephone at (800)328-6170.
  • Page 3 Table of Contents Section A. System Manager Configuration options Section B. System Manager Electrical Requirements 1) Electrical Requirements 2 2) Power Wiring 3 3) Horn Wiring 4-5 4) Run/Stop 6-7 Section C. System Manager Configuration 8-11 Section D. System Manager Operation Manual 12-47 1) Reference Page A 46 2) Reference Page B 47...
  • Page 4 Section A System Manager Configuration Options XM XS Comments Pieces of XL/XM Enclosure Dimensions: 30” x 30” x 11” (21” display) Equipment (Max) XS Enclosure Dimensions: 24” x 24” x 11” (15” display) Nodes 9.52” x 7.7” x 6.1” (Box Dimensions) Sensors per Node 2 are dedicated to ambient temperature monitoring Sensors (Max)
  • Page 5 Section B System Manager Electrical Requirements These are the electrical requirements for the System Manager. It explains the proper conditions and configuration options. The system Manager should be installed, powered, and have the proper con- figuration completed prior to installing the Nodes or the Sensors. For the best commissioning results follow the recommended installation sequence.
  • Page 6 Power Supply Wiring AC Hot goes to terminal on circuit breaker AC Neutral goes to rst terminal on +V +V -V -V top row +V +V -V -V Earth Ground goes to grounding bar (Lower left of panel) Earth Ground Page 3...
  • Page 7 Horn Relay Options Model XS ONLY Horn connection to Gateway Board Horn 115 VAC Neutral N.O. 115 VAC Hot HazardPRO Gateway Board Page 4...
  • Page 8 Horn Relay Options *For HazardPRO XM & XL System Managers Horn connection to Relay I/O Board HazardPRO Relay I/O Board Alarm 115 VAC Hot Horn 115 VAC Neutral Page 5...
  • Page 9 - Closed when Run Command is present No Shutdown Alarm condition - Open when there is no Run Command 6111 Blue Circle Drive • Minnetonka, MN 55343 952-930-0100 • 800-328-6170 • electro-sensors.com Shutdown Alarm condition is present © 2015 Electro-Sensors, Inc. 3-Phase Power...
  • Page 10 - Closed when Run Command is present No Shutdown Alarm condition - Open when there is no Run Command 6111 Blue Circle Drive • Minnetonka, MN 55343 952-930-0100 • 800-328-6170 • electro-sensors.com Shutdown Alarm condition is present © 2015 Electro-Sensors, Inc. 3-Phase Power...
  • Page 11 Section C System Manager Configuration Model XS ONLY Gateway 4 Gateway 3 Gateway 2 Gateway 1 (Optional) (Optional) Alarm +24VDC Power Supply Main Power Switch Network Switch XS System Manager - with 2 pairs of Gateways XS System Manager - With Two Pairs of Gateways Page 8...
  • Page 12 EARTH +24VDC Power Supply Router Main Power Switch ELECTRO-SENSORS, INC. 4 RELAY I/O MODULE 535-056111 REV ELECTRO-SENSORS, INC. 4 RELAY I/O MODULE 535-056111 REV ELECTRO-SENSORS, INC. 4 RELAY I/O MODULE 535-056111 REV ELECTRO-SENSORS, INC. 4 RELAY I/O MODULE 535-056111 REV...
  • Page 13 EARTH +24VDC Power Supply Router Main Power Switch ELECTRO-SENSORS, INC. 4 RELAY I/O MODULE 535-056111 REV ELECTRO-SENSORS, INC. 4 RELAY I/O MODULE 535-056111 REV ELECTRO-SENSORS, INC. 4 RELAY I/O MODULE 535-056111 REV ELECTRO-SENSORS, INC. 4 RELAY I/O MODULE 535-056111 REV...
  • Page 14 EARTH +24VDC Power Supply Router Main Power Switch ELECTRO-SENSORS, INC. 4 RELAY I/O MODULE 535-056111 REV ELECTRO-SENSORS, INC. 4 RELAY I/O MODULE 535-056111 REV ELECTRO-SENSORS, INC. 4 RELAY I/O MODULE 535-056111 REV ELECTRO-SENSORS, INC. 4 RELAY I/O MODULE 535-056111 REV...
  • Page 15 Section D Operation Manual 6111 Blue Circle Drive • Minnetonka, MN 55343 phone: 952-930-0100 • toll free: 800-328-6170 • fax: 952-930-0130 web: electro-sensors.com • e-mail: tech@electro-sensors.com Page 8 Page 12...

  • Page 16: Table Of Contents

    Table of Contents Page Number Chapter 1 - Status Main View Detail View Temperature Live Chart Speed Calibration Chapter 2 - Event Resolution Chapter 3 - History Input types and descriptions Chapter 4 - Administrative Tools Equipment Configuration 21-26 Event Archive Facility Information Gateways Interval Mode...

  • Page 17: Chapter 1 - Status

    Status This menu selection displays the equipment being monitored and the available space for equipment expansion. The menu will allow you to select any piece of equipment. Once selected (highlighted) the equipment Name, Status and Section areas will be visible. Status View: Figure 1 1.

  • Page 18: Detail View

    To view sensor details, select the desired Section (Figure 2). The equipment sec- tion will then display each sensor being monitored. Each sensor input will be in numeric sequence. Selecting Details will open a detailed view of each input, and will allow a graph to be displayed.

  • Page 19: Live Chart

    Live Charts: Figure 5 Displays the name of the Input, type of measurement, and the following details (Fig- ure 5): 1. Green signifies equipment is running (green bar). 2. The measured value (black line). 3. Heartbeat (dots on the black line) displays either the primary or the secondary transmission.

  • Page 20: Chapter 2 - Event Resolution

    Event Resolution This menu displays any event when a condition is detected outside the normal or preset parameters. This section will display: the event, cause, time, and will provide a graph. It will then allow the user to add comments about the event and the resolution.

  • Page 21: Chapter 3 - History

    History This menu displays the historical information for each piece of equipment: Section (Node) and Input. Data is available for a selected date and time range. History: Figure 10 1. Select History tab from the main side menu. 2. Select options from the drop-down menus. 3.

  • Page 22: Input Types And Descriptions

    Input description table: Input Description Battery Voltage Reads the battery voltage. Sensor Power Voltage Reads the sensor voltage. Signal Strength Reports the node signal strength in Decibels. Elapsed Time Reports the time between transmissions. Packet Difference Reports the number of data packets transmitted over time.

  • Page 23: Chapter 4 - Administrative Tools

    Administrative Tools This section has many administrative functions. Only Administrator, Corporate Manager, and Facility Manager accounts can access Administrative Tools. Subsections include: Equipment Configuration, Event Archive, Facility Information, Gateways, Interval Mode, Plant Control System Interface, Remote Notification, Slow-Down Testing, Slow-Down Testing Reports, System Wide Hazard Monitoring Settings, and Users.

  • Page 24: Equipment Configuration

    Equipment Configuration: This tool allows the user to add, edit, and delete equipment from the system. This includes the identification of each Section and the connected Sensors. Administrative Tools Subsections: Figure 11 Figure 12 Managing Equipment: Figure 13 Figure 14 1.
  • Page 25 Equipment Configuration: Equipment General Figure 15 Select the Equipment General. The equipment can be named, put In Use, and Bypassed. 1. This will become the name on the System Manager Status screen (Only the Adminis- trator can change this.) 2. Select whether the equipment is being actively monitored. 3.
  • Page 26 Equipment Speed and Run Time: Figure 16 Figure 17 1. This allows you to select a primary speed display in the Status section of the main display. Page 23...
  • Page 27 Sections A through F Figure 19 Figure 18 When you select a Section the Node General will highlight and allow the user to define or change the Node Parameters. 1. If the Node ID is unassigned, Select the appropriate available ID (Serial Number should match the ID on the Node’s side label).
  • Page 28 Inputs 1 Through 6: Temperature There are six inputs identified specifically for temperatures. Ambient Temperature Control Fixed Temperature Control Figure 20 Figure 21 1. Record the name for the sensor as you want it displayed on the System Manager. 2. Select whether or not you would like the sensor to be placed In Use. 3.
  • Page 29 Input 7 Speed: One input per Section is reserved for sensing speed. Figure 22 Input 8 Contact: Figure 23 1. Record the name for the sensor as you want it displayed on the System Manager. 2. Select whether or not you want to have the sensor put In Use. 3.

  • Page 30: Event Archive

    Event Archive: View archived (historical) events that have been logged within the System Manager. These events identify why the record was created and which steps were taken to resolve the situation. They reference the date and time in which the event was logged.

  • Page 31: Facility Information

    Facility Information: This section manages information about the physical location of the System Manager Administrative Tools Subsections: Figure 23 This information shows on the Status screen. 1. Facility Information should be filled out in this section. 2. To change the facility name on the home page you must change the company and name fields in the Facility Information settings.

  • Page 32: Gateways

    Gateways: Administrator Access Only This utility manages the gateway connection settings. Caution: these settings can only be changed by a System Administrator, and will affect communication with nodes if altered. Administrative Tools Subsections: Figure 26 1. Gateways always come in pairs. 2.

  • Page 33: Interval Mode

    Interval Mode: Interval Mode allows the user to enable systems to run on intervals. This can be utilized for applications such as cold weather operations. Administrative Tools Subsections: Interval Mode Options: * When Interval Mode is enabled a notification will appear on the status screen.

  • Page 34: Plant Control System Interface (Pcsi)

    Plant Control System Interface (PCSI): Authorized Access Only The Plant Control System Interface (PCSI) page allows the Sys- tem Administrator to change the communication settings for use with PLC I/O, Relay I/O, or Gateway I/O. Administrative Tools Subsections: Figure 28 Note: •...
  • Page 35 Figure 29 Figure 30 Figure 31 PLC I/O - Server host address should match network of the PLC. (Figure 29) Relay I/O - IP address must match Relay I/O board IP for proper operation (Figure 30, 31) Page 28 Page 32...

  • Page 36: Remote Notification

    Remote Notification This section is used to set which events trigger remote notifica- tion to the listed users. Administrative Tools Subsections: Remote Notification, General Settings: Remote Notification, E-mail Server Settings: Figure 30 Figure 31 1. Notifications can be enabled for each failure type. (Fig 30) by user 2.
  • Page 37 Slow-Down Testing: Caution Slow-Down testing is a tool that can be used to ensure that the hazard monitoring system is working properly. Slow-Down Test- ing Will stop your machinery so take the necessary precautions. Slow-Down Testing will simulate a slow down to confirm warnings and shutdowns operate properly.
  • Page 38 Slow-Down Testing: Visual and Audible Testing Slow-Down Testing: Visual and Audible Testing Figure 33 Figure 34 Slow-Down Testing: Visual and Audible Testing Results Figure 35 1. Begin the alarm test. 2. Answer the following questions based on the results of your test. Page 35...

  • Page 39: Slow-Down Testing

    Slow-Down Testing: Equipment Testing Figure 36 Slow-Down Testing: Equipment Testing Results Figure 37 1. This portion of the test confirms that all of the components of your hazard monitor- ing system are working correctly. You can either initiate a test or choose to skip. 2.
  • Page 40 Slow-Down Testing: Alarm Re-Enableing Figure 38 Slow-Down Testing Completion Screen Figure 39 1. This screen shows a second alarm condition to confirm correct operation. 2. When you see the page showing the speed plotted on the graph it means that your test is complete.

  • Page 41: Slow-Down Testing Reports

    Slow-Down Testing Reports After running slow down testing, it will generate a report. This report will show the user which components of the overall system passed or failed the slow-down testing. These reports can be viewed at any time through the Slow Down Testing Reports menu. Administrative Tools Subsections: Figure 40 1.
  • Page 42 Slow-Down Testing Report: Figure 41 1. To print the Slow-Down Testing Report, Click the Print button in the upper right corner of the report. Page 39...

  • Page 43: System Wide Hazard Monitoring Settings

    System Wide Hazard Monitoring Settings This area is where global settings can be set for the System Manager. These settings can be overridden by higher priority settings in other areas of the System Manager (System Manager always uses lower temperature set-points if there are contradicting values).
  • Page 44 Figure 43 Figure 44 Figure 45 1. Security Policies sets the authorization levels of the different account types. (Figure 43) 2. Event Management sets a maximum time to keep events in the Event Resolution section before automatically archiving the event. All events can also be archived or deleted on this page.
  • Page 45 Figure 46 Change Set-Points Globally can be used to edit all current set points across all pieces of equipment by sensor type. Warning: custom warning and shutdown temperatures will be overridden and must be re-entered by applying set points. Page 38 Page 42...

  • Page 46: Users

    Users: This section manages user accounts and their corresponding user level. Users can be added/removed to/from the system and given one of five different user levels. Administrative Tools Subsections: Add a New User: 1) Click “Add New User” to add a new user to your system manager.
  • Page 47 Modify existing user: Figure 49 Figure 50 1) Select User to edit. 2) Click Modify User 3) After appropriate changes have been made, click “Save Changes”. 4) Delete User Note: Users cannot modify accounts with a higher clearance level. • For User Privileges view Document B.

  • Page 48: About

    About The About page shows general information regarding Electro-Sensors that may be helpful to the customer for con- tact and support. Software versions can also be referenced in this section. Figure 51 Page 45...

  • Page 49: References

    References Reference Document A: HazardPRO System Manager Temperature Set-points The following are set in the General tab: Setting Run Request Speed Slug Setting Fail-Safe Shutdown Temperature Latency Warning Delay Measurement Seconds Seconds Measurement Fahrenheit Celsius Default 2 Seconds 10 Seconds Default 175°F 79°C...
  • Page 50 Reference Document B: Account Creation Clearance Level Viewer Employee Facility Manager Corporate Manager Administrator Viewer Employee Facility Manager Corporate Manager Administrator Administrative Tools Access Guide User Profile Equipment Event Facility Gate- Interval PCSI Remote Slow Slow Down System Users Configuration Archive Info ways...
  • Page 51 Section E Hazard Monitoring Modbus Equipment Run Request Interface Overview The Equipment Run Request Equipment States Remarks Value Stopped Plant control system has equipment stopped. 0X0000 Run Requested Plant control system has equipment running. 0X0001 Factory Default Settings 192.168.0.51 Port: Device ID: 1 (Base 10), 0X01 (Hex) Time-out:...
  • Page 52 Equipment Starting Addresses Equipment ID Starting Address 1001 1201 1401 1601 1801 2001 2201 2401 2601 2801 3001 3201 3401 3601 3801 4001 4201 4401 4601 4801 5001 5201 5401 5601 5801 6001 6201 6401 6601 6801 7001 7201 *All Values are base 10 unless expressed in hex notation (0X00) Page 49 Page 49...
  • Page 53 MODBus Read Command Example Most PLC’s have simple ladder instructions that read and write Modbus values. The following information details the data packet layout of the Modbus transactions. In most cases, it will not be necessary to understand the content of the transaction to utilize the PLC instructions Example Read Example request to read registers 401 to 403 Request...
  • Page 54 Response Structure The register data in the response message are packed as two bytes per register, with the binary contents right justified with each byte. For each register, the first byte contains the high order bits and the second contains the low order bits. Byte Description Default Value...
  • Page 55 Hazard Monitoring Modbus Equipment Run Request Interface Example Write registers 0001 to 0003 (This would represent Equipment 1, 2, and 3.) In this example Equipment 1 and 3 are running and equipment 2 is stopped. Request Response Field Name (Hex) Field Name (Hex) Function 0X10...
  • Page 56 Hazard Monitoring Modbus Equipment Run Request Interface TCP/IP Data Packet Detail (Request Structure) Byte Description Default Value Remarks Transaction Identifier High Byte Number to track request. Response will include this number. Transaction Identifier Low Byte Protocol Identifier High Byte All Modbus commands must be protocol 0.
  • Page 57 Hazard Monitoring Modbus Equipment Run Request Interface TCP/IP Data Packet Detail (Request Structure) Byte Description Default Value Remarks Transaction Identifier High Byte Will be same number as request which started this response Transaction Identifier Low Byte Protocol Identifier High Byte All Modbus commands must be proto- col 0 Protocol Identifier Low Byte...
  • Page 58 Hazard Monitoring Modbus Equipment State Interface Overview The Equipment State Interface will give the PLC access to the general status of each piece of equipment attached to the system. This can be used to simply display information on control screens or to close gates and shutdown equipment. Each piece of equipment can be in one of five states- not in use, normal / ok, bypassed, warning, and forced shutdown.
  • Page 59 Hazard Monitoring Modbus Equipment State Interface Most PLCs have simple ladder instructions that read and write Modbus values. The remaining information details the format of the Modbus transactions. In most cases, it will not be necessary to understand the content of the transaction to utilize the PLC instructions. Example Read Example request to read registers 201 to 203 Request...
  • Page 60 Hazard Monitoring Modbus Equipment State Interface Response Structure The register data in the response message are packed as two bytes per register, with the binary contents right justified within each byte. For each register, the first byte contains the high order bits and the second contains the low order bits.
  • Page 61 Section Starting Offsets Section ID Starting Offset +128 +160 Equipment ID & Section ID Starting Addresses Equipment ID & Starting Address Section ID 1001 1033 1065 1097 1129 1161 1201 1233 1265 1397 1329 1361 7201 7233 7265 7297 7329 7361 *All Values are base 10 unless expressed in hex notation (0X00) Page 58...
  • Page 62 Section Starting Offsets Equipment Section Offset Name Values Node State +128 +160 0 = Not in Use 1 = Normal / OK 2 = Bypassed 3 = Warning 4 = Forced Shutdown Communication Link Status +129 +161 0 = Link has timed out 1 = Link is OK Node Health Status +130...
  • Page 63 Section Register Example Equipment 1 Equipment Section Name Values Node State 1001 1033 1065 0097 1129 1161 0 = Not in Use 1 = Normal / OK 2 = Bypassed 3 = Warning 4 = Forced Shutdown Communication Link Status 1002 1034 1066 1098 1130...
  • Page 64 Hazard Monitoring Modbus PCSI Equipment RPM Link Overview The PCSI Equipment RPM Link gives access to the current RPM of each piece of equipment attached to the system that has a speed section assigned to it via a Modbus interface. Factory Default Settings 192.168.0.51 Port:...
  • Page 65 Equipment RPM Registers Equipment Number Modbus Address Register Values (Base 10) (Base 10) Type Word Word Word Word Current RPM Word Word Word Word *All Values are base 10 unless expressed in hex notation (0X00) Page 51 Page 62...
  • Page 66 Section F Wireless Antenna Guidelines This instruction guideline will identify the different antennas, options, mounting, coaxial cable and technique required for proper installation. Safety: “Lock out tag out” the system, or determine that the system is safe while installing the antennas and coaxial cable.
  • Page 67 Wireless Antenna Guidelines Antenna Options: • External antenna whip (multi-directional, adjustable) • Omni antenna (multi-directional) • Patch/Panel antenna (directional, requires aiming & precision) Mounting Options: • Never drill holes in the antenna body. This can damage the antenna. Only drill holes in the bracket or the mounting structure.
  • Page 68 Wireless Antenna Guidelines Coax Cables and Connections Cable: • Utilize the Coaxial cables provided, ensure the end connectors are clean and free of debris. If you are terminating a coaxial cable ensure that the center pin and grounding shields are correct (detailed coaxial termination instructions are available on page #: 69) •...
  • Page 69 Wireless Antenna Guidelines Examples and Templates Single Patch antenna mounted to a RAM bracket Two Omni Antennas mounted on antenna bracket Single bracket template (you will need to select or drill holes to match the antenna and the mounting method) Two panel antennas mounted to RAM brackets Two omni antennas using antenna hardware External Whip attached to side of Node...
  • Page 70 Section G Coaxial Termination Instructions This Section covers basic instructions on how to install end connectors for coaxial cable. There are different types of cables and end connectors. Safety: Wear safety glasses to prevent metal braid from injuring eyes. The sharp edges of the cable can easily cut or scratch you.
  • Page 71 Step 1: Prepare the coaxial cable end 1) Make a clean cut on the cable and prepare for cable stripping. Note: You will need to have the correct end connector (components section), stripping tool, and crimp tool (tool index table) before proceeding to the next steps. Step 2: Cut and strip the coaxial cable end.
  • Page 72 Photos and Examples for each Termination Step Step 1: Prepare the end Step 2: Cut and strip - Extend the Coaxial Cable beyond the body of the stripping tool, after stripping, check and center conductor length. Reference the Pin Termination Table. Remove this end piece Do not cut into metal braid Step 3: Install the Pin on conductor end...
  • Page 73 Additional Crimping Tips Place the pin in the correct crimp jaws Close the crimp tool to barely hold the pin Fully Insert the conductor into the pin, then crimp the pin Instructional Video (https://youtu.be/UtSo7tFvRCw) Page 70...
  • Page 74 Notes Page 71...
  • Page 75 Notes Page 72...
  • Page 76 HPSM100 Rev C © 2019 Electro-Sensors, Inc. All rights reserved. HazardPRO is a Trademark of Electro-Sensors, Inc.

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