Mesa Laboratories 90-0143-001 SCHNEIDER TEMPERATURE SENSOR User Manual 1

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Wireless Temperature

Monitoring System

HAZARD CATEGORIES AND SPECIAL

SYMBOLS Read these instructions carefully and look at the equipment to become familiar with the

device before trying to install, operate, service or maintain it. The following special

messages may appear throughout this bulletin or on the equipment to warn of potential

hazards or to call attention to information that clarifies or simplifies a procedure.

The addition of either 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.

PLEASE 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.

FCC NOTICE This equipment has been tested and found to comply with the limits for a Class A digital

device, pursuant to part 15 of the FCC Rules. These limits are designed to provide

reasonable protection against harmful interference when the equipment generates, uses

and can radiate radio frequency energy and, if not installed and used in accordance with

the instruction manual, may cause harmful interference to radio communications.

Operation of this equipment in a residential area is likely to cause harmful interference in

which case the user will be required to correct the interference at his own expense. This

Class A digital apparatus complies with Canadian ICES-003.

FCC RADIO FREQUENCY

INTERFERENCE STATEMENT 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. These 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:

•Reorient or relocate the receiving antenna;

•Increase the separation between the equipment and receiver;

•Connect the equipment into an outlet on a circuit different from that to which the

receiver is connected.

NOTE: Consult the dealer or an experienced radio/TV technician for help.

DANGER

cDANGER indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not

avoided, can result in death or serious injury.

CAUTION

CAUTION, used without the safety alert symbol, indicates a potentially

hazardous situation which, if not avoided, can result in property damage.

Provides additional information to clarify or simplify a procedure.

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03/2011 Application Notes and Installation Manual

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

SECTION 2 RECEIVING, HANDLING AND STORAGE

SECTION 3 APPLICATION NOTES AND SPECIFICATION

SECTION 4 WTMS INSTALLATION

SECTION 5 VALIDATION TESTS FOR WTMS PARTS AND PERFORMANCE

SECTION 6 REFERENCES

SECTION 7 FCC NOTE

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SECTION 1

SAFETY PRECAUTIONS In this section:

This section contains important safety precautions that must be followed

before attempting to install, service, or maintain electrical equipment.

Carefully read and follow the safety precautions outlined below

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

• The hardware of Wireless Temperature Monitoring System, the

sensors, may be installed only on completely de-energized and

removed out-of-service electrical equipment, such as circuit breakers or

switches. To de-energize apply appropriate personal protective

equipment (PPE) and follow safe electrical work practices. See NFPA

70E

• Only qualified personnel familiar with electrical equipment are to

perform work described in this set of instructions.

• Perform such work only after reading and understanding all of the

instructions contained in this manual.

• The circuit breaker must be in the open (O) position.

• All circuit breaker springs must be discharged.

• Switchgear primary conductors should be grounded.

• 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 or other property.

• Carefully inspect your work area and remove any tools and objects left

inside the equipment.

• All instructions in this manual are written with the assumption that the

customer has taken these measures before performing the installation

of wireless sensors inside electrical equipment.

Failure to follow this instruction will result in death or serious injury.

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SECTION 2

RECEIVING Upon receipt, check the packing list against the equipment received to

ensure the order and shipment are complete. Claims for shortages or errors

must be made in writing to Schneider Electric within 60 days after delivery.

Failure to give such notice will constitute unqualified acceptance and a

waiver of all such claims by the purchaser.

Immediately inspect the equipment for any damage which may have

occurred in transit. If damage is found or suspected, file a claim with the

carrier immediately and notify Schneider Electric. Delivery of equipment to a

carrier at any of the Schneider Electric plants or other shipping points

constitutes delivery to the purchaser regardless of freight payment and title.

All risk of loss or damage pass to purchaser at that time.

For details concerning claims for equipment shortages and other errors,

refer to Schneider Electric “Terms and Conditions of Sale.”

HANDLING Use care when handling the wireless temperature monitoring hardware.

STORAGE When the parts are not in use keep them in a clean, dry, heated corrosion-

free area where it is protected from damage. When the monitoring system

hardware is stored for prolonged periods, inspect it regularly for overall

condition.

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SECTION 3

APPLICATION NOTES AND

SPECIFICATIONS 3.1. System Description

The Wireless Temperature Monitoring System (WTMS) monitors tempera-

tures of the surfaces of energized electrical equipment (see Section 6, Ref

[1], Product Specifications 16090-10).

The system consists of three components:

•Sensors (wireless transmitters)

•Receivers (signal receiving units)

•Software (processing, alarming and reporting software)

Square D High Temperature Sensors are designed to actively measure the

temperature of the strategically important points on metal or insulating sur-

faces of current carrying parts. The Sensor design allows measuring the tem-

perature in wide range, from 0 to 150o C. The Receiver receives the RF

signals from the Sensors with temperature, time stamp and identification in-

formation from the Sensors and relays this information to PC.

Software processes the sensor information and records it into a textual log

file. Two versions of software are available: one providing the system working

in standalone mode (TempAssure), another in conjunction with power moni-

toring system. A version of the Receiver is also available for integration into

SCADA and BMS systems.

3.2. How WTMS Works

WTMS is quickly and easily installed in any facility by deploying multiple Sen-

sors in positions throughout energized equipment to continuously monitor

surface temperature. The Sensors transmit a packet every twelve minutes,

or, if the temperature is increasing fast, every six minutes.

The packet is picked up by a near Receiver/Receiver. Receivers have a typ-

ical indoor range of 100 feet with sensors mounted in equipment. The Re-

ceiver (antenna) is centrally installed in the control room (a single Receiver

can receive information from 100 sensors). However, it is recommended to

utilize at least 2 Receivers for a given area to maximize reception of the RF

signals from the Sensors.

Depending on number of the Sensors in the system and the size of facility, a

series of the Receivers can be connected in daisy chain. Once the data is

picked up by the Receiver the data is placed on the Receiver network. The

Receiver network uses standard category 5 Ethernet Cable to daisy chain

the Receivers supplying power and a way to communicate back to the PC.

Another option is to transfer the data to PC via multiple ethernet ports.

A PC installed at the facility or the existing facility network is used. In standa-

lone mode of WTMS the TempAssure Software is installed on local PC and

sensing parameters are set (WTMS allows adjusting alert conditions to Cus-

tomer specific needs). Temperature information may be reviewed by the Cus-

tomer or by Square D Engineering Support (see Section 6, Ref [2], Product

Specifications 16090-11- WTMS Consulting Services) via modem or Internet.

Alerts or reports can be sent to the customer in numerous ways such as by

cell phone, two-way pager, or email. Web monitoring is also an option.

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3.3. System Features

Easy Installation - Installation of software and Receiver is simple. Affix the

receiver to conduit or strut and provide power. The software is also easy to

install.

Monitoring - Software allows monitoring of the temperature readings from

all active Sensors.

Range - Antenna receives Sensor signals up to 100 feet (30 meters) away

(tested successfully up to 1000 ft.).

Population - The system can monitor an unlimited number of Sensors with-

out interfering with one another or loss of identification.

Supervision - Sensors transmit a signal every 6-12 minutes depending of

thermal condition, so you can respond quickly to any problems.

3.4. Square D High Temp Sensors Features

The Sensors are all-in-one temperature sensors and identification tags (Fig

1). The Sensors detect ambient temperature and continuously send radio fre-

quency information to the Receiver. The device transmits the information it

has collected using a low power RF transmission. The Sensors are calibrated

accordingly to application to give accurate temperature readings. Re-calibra-

tion is not required.

Figure 1: Wireless Square D High Temperature Sensor

Low Cost Installation - The Sensors are wireless and can be placed almost

anywhere by using a high temperature adhesive.

Operation - In direct contact with the surface.

Long Battery Life - Sensors utilize a High Temperature 3V lithium battery

that lasts up to 5 years.

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3.4.1 Application Sensors

Wireless sensors can be applied to any type of new or used LV and MV elec-

trical equipment such as switchgear, circuit breakers, capacitor banks, trans-

formers, motors, busways and cables. The Sensors can be also used on HV

and EHV electrical equipment.

The Sensors can be applied for measuring temperature of any strategically

important points inside energized apparatus, such as stationary contacts, fin-

ger clusters, stabs, bolted connections, as well as any other important loca-

tions where temperature should be controlled. The number of points to

monitor inside the unit is not limited. It is considered important to install the

Sensors on each phase of the apparatus both on load and line side. Some-

times it is possible to detect a problem based on lesser number of the Sen-

sors, for example only on load side, but this decision should be made based

on design and application features. The only limitation is applying the Sen-

sors would be the dimension of the space available at the point of interest,

which should be not less than 1.5 x 1.5 x 1.5 inch3 (4 x 4 x 4 cm3). The Sen-

sors can be attached to either metallic or insulating surfaces and in any po-

sition using installation technique and adhesives recommended in section

4.1.1.

Examples of Sensor installation points are shown in Fig. 2 for LV and MV cir-

cuit breakers. Fig. 3 and Fig. 4 show positions of the Sensors on the bus

stabs and cable connections inside LV switchgear, and MV switchgear, as

well as suggested positions of the sensors for measuring temperature of am-

bient air inside the cells.

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Figure 2: Wireless temperatures sensors on finger clusters of LV

and MV Circuit Breakers.

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Figure 3: Wireless temperature sensors on buses and bolted cable

connections inside LV switchgear.

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Figure 4: Wireless temperature sensors on stabs and bolted cable

connections inside MV switchgear.

3.5. Sensor Specifications

Type: Sensor and Radio Frequency Transmitter .

Physical Dimensions: Sensor casing: D=1.5 in. (40 mm), H =1 in. (25 mm)

Weight: < 20 g (0.7oz.)

Enclosure: Non-conductive, High T and UL tested, waterproofed for humid

and corrosive environment

Operating Temperature: Low: 0º C (32º F); High: 150º C (300º F)

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Transmission Range: 100 ft. (sensors installed in switchgear).

Mounting Location: On flat clean surface using High T adhesive.

Transmission Frequency: Transmittance intervals change based on the

rate of the temperature change: Signal is transmitted by the Sensor every 12

minutes. However, in case of a temperature rise of 3º C per minute the Sen-

sor will transmit every 6 minutes.

Battery: High temperature 3V lithium battery, easily replaceable in the field.

3.6. WTMS Receiver Features

The WTMS monitors all Sensors, actively measuring temperatures in a se-

lected area. The Receiver constantly monitors and listens for transmissions.

The Receiver determines if a signal is valid or if it is noise to be filtered out,

then mark the transmissions with the proper packet and send it via a network

to a computer for processing.

The Receiver utilizes Spread Spectrum Technology (SST). It is available in

three different versions (Fig.5), plus a repeater version.

— Serial SST Receiver receives transmissions and sends them to a PC

via RS-485 using a Connection Kit (RS-485 to RS-232 Converter).

Serial REceivers to be connected, in series, for large coverage

areas.

— SST Receiver with wired Ethernet Connection (802.3).

— Wireless Extension SST Receiver, which provides wireless

transmission of the RF signals to a wired SST Receiver thus

doubling the distance between the transmitters and receiving units.

— Ethernet SST Receiver with Modbus TCP communication protocol.

Power must be supplied to the Receiver by using the power transformer

supplied with the Receiver. For the Serial SST Receiver, another option is to

supply power via the RS--485 network using power from the Connection Kit.

This option is ideal for a Receiver mounted in an area that does not have a

convenient power source.

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Either the Serial or 802.3 Ethernet type of wired Receiver accepts

temperature and identification information from the Sensors and relays the

information to the TempAssure Software (see section 4.2), which displays

the activity of all wireless Sensors and logs their temperature readings into a

text file for future reference and analysis. A diagnostic screen allows the

user to monitor the system for any problems in the sensory network.

Figure 5: SST Receivers: Serial, Wired Ethernet, and

Wireless/Extension versions.

3.7. Receiver Specifications

3.7.1 SST Receiver Specifications

Type: Spread Spectrum Technology

Frequency Range: 902-928 MHz

Physical Dimensions: 6in. x 4in. x 1.25in. (15cm x 10.2cm x 3.2cm)

Weight: 1/2 lb.

Minimum Reception Range: Omni-directional 300 ft. line-of-site. Range re-

duced by obstructions.

Connection/Communications:

—Serial SST Receiver: RJ-45/RS-485 link to computer. 115,200 baud,

no parity, 8 bits, one stop bit, asynchronous link to computer.

—Ethernet SST Receiver: RJ45 Power (2.1mm)

Power Requirements: 6VDC, 500 mA

Mounting Location: Hanging on a pole, or attached to a flat, clean surface

using adhesive

Operating Temperature: -28ºC to 85ºC (-18ºF to 185ºF)

Accessories: Square D High Temp Sensors.

Bus Adapter Kit: Serial SST Receiver: Connection Kit - RS232 TO RS485

Converter; 7ft. CATS RJ45 Cord; and 485PS - Power Supply

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Bus Protocol:

—Serial SST Receiver: Proprietary

— Ethernet SST Receiver (802.3): Proprietary

— Ethernet SST Receiver (Modbus): Modbus® TCP

Certifications: Part 15 FCC approved, CE certified

3.7.2 Ethernet SST Modbus® Receiver Connectivity

Ethernet SST Receiver with Modbus® TCP Protocol is equipped with both

an Ethernet port and an RS-485 Serial port, which allows using it as a Serial

SST Receiver. This function is provided to facilitate WTMS setup

preparatory procedure. This option could be utilized in optimization of

sensing and receiving units’ positions, while using a simple standalone

version of the system software. This version may be also used prior to

WTMS integrations into a customized monitoring system.

In Fig. 6, position of the ports for Ethernet cable and DC power input for

utilization of the Modbus® module are shown. The third port is designated

for connecting the Receiver to PC via connection kit (shown in Fig.10)

directly or using an optional Ethernet Serial Server. The use of Serial

module would require a connection kit and TempAssure software installed

on local PC. When the Serial module is utilized, the receiver will be powered

via a power supply that is included in the connection kit (the power input on

the receiver will not be utilized).

Figure 6: Positions of the Ports on the Ethernet SST Receiver with

Modbus® TCP.

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SECTION 4

WTMS INSTALLATION 4.1. Installation of Temperature Monitoring Hardware

Hardware of Wireless Temperature Monitoring System consists of the set of

temperature monitoring devices (wireless temperature sensors), signal re-

ceiving devices (Receivers) and connecting kit for connecting the Receiver

to PC and supplying power to the Receiver.

4.1.1. Installation of the Sensors

Use the following procedure to attach wireless Sensor to the part for which

the temperature is to be measured. The Sensor can be installed on any flat

surface made of metallic materials. The Sensor cannot be installed on any

movable contacts or lubricated areas.

Surface preparation note: If Sensors are installed on metallic surfaces on

current carrying part, on insulation, or on compartment doors, the surface

should be cleaned from any dust, particulate matter and moisture with a

clean dry cloth. If needed, use a mild cleaner to remove grease or dirt from

the surface.

Adhesives:

1. RTV Silicone Adhesive (requires about 24 hours curing at room

temperature), such as GE Silicone II Premium Waterproof Silicone,

stock number GE500 90642.

2. Instant adhesive (“super glue”) should hold the sensor in place long

enough for the silicon to cure. It is rated for about 125ºC (~260º F), so

CAUTION

HAZARD OF EQUIPMENT DAMAGE

• Wireless Temperature Monitoring for use with Low Voltage and Medium

Voltage electrical equipment.

Failure to follow this instruction can result in equipment damage and

void the warranty.

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH

• Install and remove Wireless Sensors only on de-energized equipment

and removed out of service electrical equipment. To remove or take out

of service any circuit breaker or switch refer to OEM manual for these

devices.

• To de-energize electrical equipment apply appropriate personal

protective equipment (PPE) and follow safe work practices. See NFPA

70E.

Failure to follow to follow these instructions will result in death or

serious injury

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the bus bar should be kept below this temperature during the curing

process.

The application procedure should be as follows:

Different views of the sensor are shown in Fig.7. It is pictured from the top

(left) and from the bottom (right), and the sensor case is shown in the

center. For installation, the units should be disassembled by removing the

lid and the sensor assembly (Fig.7) from the case. The case should be

glued onto the equipment surface with the bottom facing the surface. After

the sensor case is attached to the surface, the sensor assembly should be

inserted into the case with the copper enclosure getting into the opening in

the case bottom and the lid should be snapped in to close the case.

1. Apply a ring of silicone in the area between the outer edge of the small

elevated ring located at the opening in the case center and the edge of

case. The silicone ring should be about 2.5mm wide, enough to seep

around the case outside edges when applied (Fig.8, left)

2. Apply four drops of “super glue” equidistantly on the surface of small

elevated ring in the center to the case (Fig.8, right). As soon as the case

is pressed to the surface, the glue will spread and cover ~100% of the

ring surface area.

3. Attach the case bottom in the position on the surface of the part for

which the temperature is to be measured as soon as possible to avoid

an early hardening of the instant glue. Press the sensor to the surface

for 2 minutes, after which it is safe to leave the case for the next 24

hours to let the silicone cure. Super glue is strong enough to hold the

weight of the sensor in any position.

4. Make sure the silicone seeps around the edge of the sensor to prevent

airflow. After the cure is complete, the RTV silicone adhesive takes over.

Figure 7: The sensor: the top of the sensor with RFID label seen through the transparent lid and the label attached to

the side of the case (left), the empty case of the sensor bottom up (center), the bottom of the assembled

sensor with the sensing element in copper enclosure inserted into the opening in the bottom of the case

(right).

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Figure 8: Sensor assembly with sensing element within copper

enclosure.

4.1.2. Installation of the Receiver

Finding the best location for the Receivers:

The key factor in a successful install, is finding the best possible location for

the Receiver. The plant walk-through will provide best opportunity to search

for a location based on the sensor array. Place readers in open areas to re-

ceive as many signals as possible. Here are a few guidelines to help when

placing the Receiver:

•Install the Receiver as high as possible

•Position the Receiver in a central location

Place the Receiver as close to the center of the location as possible to

maximize the reception of the antenna. If a central location is unavailable,

look for the best possible sit in relationship to the sensors.

•Keep the Receiver away from Interference.

Figure 9: RTV Adhesive ring on the bottom of the case (left); drops of super glue on the inner elevated ring (right).

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The receiver is designed to work in noisy environments but it is hindered if

placed near (within 5 feet) the following devices:

— Florescent Lighting Fixtures

— Computers and Monitors

— TV’s and Radios

— Large Metal Objects

— Telephone and Network (Ethernet) equipment

— Other items that may block or absorb RF signals which may cause

blind spots to Receivers, such as thick concrete walls, air-

conditioning units.

Suggested mounting methods for Receivers: the Receivers should be

mounted with a minimum of 1 in. separation from flat surfaces such as walls,

rafters, etc. Steel walls and rafters especially require separation to get good

reception.

4.1. 3. Assembly of Connection Kit (Serial Receiver to PC connection)

Parts in Connection Kit:

1. DB25M-DB9F converter

2. RS-232 to RS-485 B&B converter

3. RJ45-DB25F converter

4. Transformer 120 VAC to 12 VDC

5. RJ45 cable (CAT5)

Assembly of Connection Kit

1. Attach the 9-pin connector of the DB25M-DB9F converter to Com port 1

(9-pin) on the back of the computer. If PC does not have 9-pin port use one

of USB ports with USB to RS-232 DB9 converter (not included).

2. Attach another end of DB25M-DB9F converter to the RS232 side of the

B&B converter. Connect the RJ45-DB25F converter to the RS485 end of the

B&B adapter. Connect the Receiver to RJ45-DB25F converter with RJ45 ca-

ble (use any of two lines on the bottom of the Receiver).

Assembled WTMS is shown in Fig. 10. If PC is located at significant distance

from the Receiver, use as long as needed RJ45 cord to connect the Receiver

to RJ45-DB25F converter. Otherwise use the cable included in the kit.

To energize the Receiver, connect the pin of power supply (transformer 120

VAC to 12 VDC) into the side of the RS485-RS232 converter and plug trans-

former into power jack. As soon as connection is made, the LEDs towards

the bottom of chassis of the Receiver begin flashing signalizing that the unit

receives RF signals from the sensors.

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4.2. Installation of Software for Standalone WTMS

4.2.1. TempAssure installation

There are two versions of TempAssure Software; one for the Serial Receiver

and one for the Ethernet Receiver. It is installed by using TempAssure Soft-

ware on CD. The installation is supported by Installation Wizard. The soft-

ware and log file will be saved on the PC hard drive in the folder C:/Freshloc.

For technical support on downloading and installation of TempAssure Soft-

ware contact Square D Services Engineering.

After installing TempAssure, open the file tassure.cfg in the Freshlock

folder. In the section of text, starting with minTime=425, make the following

edits:

— At the end of the section, add the line: See TwiceWithin=7200.

— Change the value after “NotSeenDisplay” to 7200.

— change the value after “MustSeeEveryTime” to 7200.

4.2.2. TempAssure Software Setup for Serial Receiver

When TempAssure launches, the window shown in Fig.11 will appear. If the

computer cable is plugged into Com 1 it will show “Serial Port 1”. If you need

to change your com port, click on the Options Tab. You will then see the

screen shown in Fig. 12.

Figure 10: Long Range Connection Kit with Serial Receiver..

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To change the com port:

(1) Type in the com port number in the box next to “Comm Port,” and press

enter.

(2) Click the box next to “Use on Restart” to place a checkmark.

(3) Click on the X to close TAssure.

(4) Restart TAssure

Receiver(s) Setup. You will now be back at the main TAssure screen

(Stats). A blinking green box (directly under “Stats”) means your Receiver is

connected and working. Once you start seeing numbers under Serial Re-

ceives, you know you are receiving data. Now that you know that everything

is working, click on the Receivers Tab (Fig.13). If the “Auto Adds” is checked

all receiving units will be automatically added.

Figure 11: TempAssure main screen

Figure 12: “Option” Tab

Figure 13: “Receiver Tab”

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This is where you type in the information for the receiver(s) you have:

(1) In the first box, type in the number (ID) of your receiver or choose one of

it is automatically added.

(2) In the second box, type in a name for your receiver (i.e. control room,

etc.).

(3) Click Save.

(4) Repeat for additional Receivers.

Note: You must type a name for the receiver in order to run Local Reports

(discussed later in this document).

Strobe(s) setup: Click on the Strobes tab (Fig.14).

You will need to input the strobe ID’s on this screen in order to view the tem-

peratures of your strobes.

(1) In the first box, enter in the number of your strobe (RFID) or click on “Auto

Adds.”

(2) The second box “xlate” is a pull down menu, select “O Fahren.”

(3) In the third box “Strobe Name,” enter in exact location the Sensor will be

placed.

(4) In the fourth box “Low”, enter in the low alert temperature in Celsius.

For high temperature application this value may be as high as maximum am-

bient temperature according to electrical standards (40 degree C).

(5) In the fifth box “High”, enter in the high alert temperature in Celsius. For

example, if it is an electrical contact, and you would not want it to go above

100 degree C, then you enter in 100 in this box.

(6) The sixth box is “Delay.” You may enter in a time interval for a sensor to

alert. The value needs to be entered in seconds. For example, if you set a

delay of 0 seconds, and your contact temperature rises up to 100 degree C,

the line with the sensor in this location would turn red on the strobe display

screen, indicating a high alert alarm.

(7) Click “Save.” You should now see your strobes (sensors) on both the

TempAssure strobe window and on the strobe display screen.

Strobe Display utility (Fig. 15) displays which sensors are installed and in

which locations, and all other information chosen in Option Tab, such as Tem-

peratures in Fahrenheit or Celsius degree, average temperatures for 15 or

60 minutes, the time stamp of last measurements, and so on.

Figure 14: “Strobe” Tab

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4.2.3 TempAssure Software Setup for Ethernet 802.3 Receiver

There is a specific version of TempAsure for the Ethernet Receiver. First,

you will need to run the Digi Device Discovery program to configure the

Ethernet Receiver to point to your TempAssure application. Lastly refer to

section 4.2.2. for the remainder of the setup, as most information still

applies to the Ethernet version.

4.2.4 TempAssure Reporting Software

The data from temperature monitoring system is transferred from the sensors

via the Receiver to TempAssure database. Standalone WTM System is work-

ing with TempAssure Software. The data collected by WTMS may be view

and analyzed using TAssure Local Report Program. LocalRpt is a reporting

tool used with the TAssure program to print a report and graph changes in

strobe temperature. LocalRpt also supports graphing of multiple Strobes for

easy comparisons between strobes. The Local Report requires that Sensors

and Receivers have names. Make sure that this has been done before start-

ing Local Report. The first step in using the reporting program is to select the

sensor locations for the report. Click on the Show Item selection button (Fig.

16). This will display a list of sensor locations (items) to choose from. Local-

Rpt automatically selects

all of the items on the list by default. If you don’t want all items included on

the report, click on the Select None button and choose the specific items.

When making your selection you may select multiple strobes by holding

down the Ctrl key and clicking on each item. Then click on the Hide Item Se-

lection Button.

The next step is selecting the time frame for the report (Fig.17). Use the

Date/Time markers to select the starting and ending point. To increase or de-

crease the Date/Time use the arrow buttons next to the Date/Time you wish

to change.

Figure 15: Strobe Display Utility

Figure 16: Local Report: choosing the sensors for display

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03/2011 Application Notes and Installation Manual

To run a report for an allotted number of days you may click the Days button

and Input a value in the Report for Last ___ Days Blank.

The report is now ready to be created. Select the type of report to use. Select

the List button and LocalRpt will gather a list of strobe entries and display

them in a report format. To create a graph select the Plot button and LocalRpt

will create a line graph from the data recorded in the TAssure.log file. Listed

below are examples of the two types of reports. Shown in Fig. 18 is an exam-

ple of the Plot type report, it creates a graph of the temperature for chosen

strobes.

Figure 17: Local Report: selecting time frame

Figure 18: Local Report Plot

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03/2011 Application Notes and Installation Manual

The data may be listed if the option “List” is chosen, then the data may be

averaged for any selected time period and presented in tabular format. The

data may be exported into text file, which is easily converted into Excel

format for further analysis.

4.3. SCADA Software Integration

Most Supervisory Control and Data Acquisition (SCADA) and other

monitoring software package have a Modbus driver either “built-in” or

available as an option. In order to connect the Wireless Temperature

monitoring system via Modbus to a software package, the Modbus TCP

WTMS receiver will need to be utilized. The following steps should be

followed to establish communications with the receiver and create a device

tag within the SCADA software.

1. The WTMS receiver will need a static IP address. The unit comes preset

with a default of 192.168.0.100.

a. To configure the IP on the receiver, put your computer on the same

subnet as the receiver (via the IP configuration of your PC).

Important: Write down your settings before making the change.

(Fig.19)

b. Change the IP information on the receiver to work with your network,

by going to the receiver website and clicking “Edit” under network

settings. (See screen capture below) The website is located at

http://<IP address of the reciever>, and can only be reached if your

computer is on the same subnet as the device.

c. Change your PC IP settings back to the original settings you

documented in step (a).

2. The receiver has a range of registers that store the information for each

sensor. The range starts at register 3801 and goes until 19800, with 20

registers allocated to each sensor.

Determine the sensor information that is stored at a specific register range

by going to the Sensor Mapping Page from the link on the main page of the

Figure 19:

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03/2011 Application Notes and Installation Manual

receiver. The table will only show entries for discovered sensors up to a

maximum of 800 entries.

A sample mapping page is displayed in the screen capture below (Fig.20).

The sensors are assigned a range by the receiver, as it detects them. The

first range of 290 registers is referred to as Table 1, and so forth.

Following is a list of useful quantities and their offsets within the range of

registers assigned to each sensor:

Example:

To read the temperature in Celsius for Sensor ID 42154 displayed in the

above diagram, you would send a ModBus read request to address

157.198.172.61, specifying the 3825 (3821 + 4), as the register number

from which to read.

In the response packet you will get the temperature in hundreths of a

degree Celsius. So if the temperature is 25 degrees Celsius you will get a

ModBus response with the number 2500.

3. Clear the current sensor table by writing one to Modbus address 50000.

This will also clear the flash tables.

4. Acquire sensor channels.

5. When all channels have been acquired (verify the sensor mapping as

described in Step 2), write the sensor directory to flash by writing the

value “2” to Modbus address 50001.

NOTE: the flash write operation could take up to a minute depending on

the number of channels acquired, so leave the unit powered up.

Figure 20:

Quantity Offset

Sensor ID (two registers) 1 and 2

Celsius Reading in Hundredths of degree C 4

Fahrenheit Reading in Hundredths of degree F 14

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03/2011 Application Notes and Installation Manual

6. Setup the Modbus application to reference the sensor table locations

acquired above.

4.4. Modbus Specifications for WTMS Modbus TCP Receiver

A. Configuration - The TCP/IP Address, Subnet Mask and Default Gateway

Address can all be addressed over the Modbus TCP network starting at

Modbus location 60,000 for 12 registers. Each octet is a separate word.

These parameters can also be configured via the configuration web

page located at http://192.168.0.100/index.htm. The web page also

allows an application name to be programmed into the device.

B. A maximum of 800 Sensor ID packets (Sensor ID/Channel) can be

addresses through the Modbus Server Interface at device id1. Only

sensor packets starting with 0x02 0x01 are decoded; all others are

ignored

C. Modbus TCP Data Space Mapping

Table 1:

Modbus Address Holding

1- 2 Sensor ID for table 1

3 Channel # for table 1

4 Reserved

5 - 6 Sensor ID for table 2

7 Channel # for table 2

8 Reserved

3113 - 3120 Sensor ID/Channel for table 800

3201 - 3250 Status Bit array

3251 - 3800 Reserved

3801 - 3830 Sensor Data Packet (table 800)

50000 (Write 1) Clear Sensor Tables (a write of any value

50001 (Write 2) Write Current Sensor Directory (a write of

any value)

50002 - 50003 (read) Master TIck count - reset when power

cycled

60000 IP Address MSB

60001 IP Address

60002 IP Address

60003 IP Address LSB

60004 Subnet Mask MSB

60005 Subnet Mask

60006 Subnet Mask

60007 Subnet Mask LSB

60008 Gateway Address MSB

60009 Gateway Address

60010 Gateway Address

60011 Gateway Address LSB

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03/2011 Application Notes and Installation Manual

D. Status Data starting at 3201 is a set of registers that provide packet

arrival status. Each bit of the status data registers maps to a Sensor

ID/channel combination. There are 800 bits (1 per Sensor ID/Channel

Packet) in this structure (50 Modbus words). The bit will be set to a 1 to

indicate that the table entry has data.

Status Bits:

First word of status (3201) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

table entry 16 ------------------^

table entry 15 ----------------------^

table entry 14 --------------------------^

table entry 1 -------------------------------------------------------------------^

Second word of status (3202) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

table entry 17 ------------------------------------------------------------------^

E. Sensor Data Packet Mapping (starting at Word 3801)

1. Offset 0: SS Channel

2. Offset 1: Sensor ISD (Two Words)

3. Offset 3: Channel and Type

4. Offset 4: Measurement (Celsius)

5. Offset 5: Reserved

6. Offset 6: Sequence Count

7. Offset 7: Signal Strength

8. Offset 8: Pre-correction

9. Offset 9: Post-correction

10. Offset 10: SSTID (2 Words)

11. Offset 12: Delta Tick Count (2 Words)

12. Offset 14: Measurement (Fahrenheit)

13. Offset 15: Reserved (Four Words)

F. Sensor Data Packets are filled in the order that packets arrive. A Sensor

ID/Channel block is assigned to a Sensor ID when the first packet for

that Sensor ID is received.

G. Diagnostic packets are stored identically to Sensor ID packets.

H. Time Stamping - 100 msec tick count resolution measured from power

on. This tick count is a double word. It resets on power on and rollover.

I. Diagnostics - If the Default Gateway IP Address has a non-zero value,

diagnostic information will be broadcast in a UDP packet on port 45000.

This packet will show the serial data received and the calculated

checksum of the packet.

J. The Sensor Directory mapping will be saved to non-volatile flash

memory when a value of two is written to the Modbus register 50001.

This information will be restored when the Gateway powers up.

K. Temperature decoding - All temperatures for sensors are shown on

Channel 12 and are two byte signed words. The values represent the

temperature measured at the time received by the gateway (minus time

to transmit which is well under 1 second). The measurement is a signed

value in 100ths of a degree centigrade and the range is in excess of

150C.

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03/2011 Application Notes and Installation Manual

L. Clear Sensor Tables - A write of one to Modbus address 50000 will clear

the stored data tables (and write the directory to flash).

M. Write Sensor Directory - A write of two to Modbus 50001 will write the

stored sensor directory to flash.

SECTION 5

VALIDATION TESTS FOR WTMS PARTS

AND PERFORMANCE Square D Services designed and arranged a set of validation tests at

independent laboratories, and provided required documentation for the tests.

Below is a listing of test providers and description of the tests' goals and re-

sults. Complete reports of all test listed are available upon request.

Testing Providers:

•Square D Services Engineering

•Square D RF Laboratory

•Freshloc Technologies

•Independent Testing Services:

— Met Laboratories

— Underwriters Laboratories

—FCC

— Nemco USA

5.1. Validation Tests provided by Square D Engineering Services

5.1.1. Calibration Technique for Square D High Temp Sensors (direct

thermal contact with the surface)

Square D Engineering developed a new calibration technique providing sen-

sor calibration in the conditions adequate to the system application. All sen-

sors are calibrated within the oven with stabilized ambient temperature with

the sensors installed on the surface of metal bus, which temperature is

changing within the range of T from 0ºC to 150ºC and controlled with TCs.

5.1.2. Testing of Adhesion Quality of Silicone RTV as HT adhesive

Two different properties of high temperature adhesive have been tested to

approve an adhesive for using it for attachment of wireless temperature sen-

sors in energized electrical equipment: (1) chemical inertness at high temper-

atures towards metallic and insulating surfaces, and (2) an ability to hold the

sensors in vertical or upside down position for the period in service. Testing

of Silicon RTV sealant at high temperature proved that the product provides

a good adhesion and is chemically inert towards the surface to which the

sensors may be attached. This adhesive leaves no residue on metal surfaces

of the bus or insulation after the sensors have been removed. Additional test-

ing was provided by Freshloc technologies on Silicone adhesive strength.

The preferred adhesive was placed on a test bus bar and allowed to cure for

24 hours. The bus bar was then heated to approximately 150ºC for two

hours. At the end of two hours, the adhesive was tested to tolerate a load of

up to 20 lbs. The bond strength measure proved that the silicone adhesive is

sufficient to hold the weight of the sensor in vertical or upside down configua-

tions.

Wireless Temperature Monitoring System

03/2011 Application Notes and Installation Manual

5.1.3. Influence of High Voltage on Sensors Performance Signal Trans-

mittance Test setup

The measurements have been conducted using HiPot Set providing high

voltage on the metal part using a Step-up VT that allows raising the voltage

up to 100 kV. Step-up VT is a source of corona by itself. Several Square D

High Temp sensors were positioned on piece of copper bus bar, which was

connected to Step-up transformer with the cable. The voltage has been

raised from 5 kV to 50 kV and held for 10 minutes at each voltage. At the last

stage of the test the voltage has been raised to 25 kV and was hold at this

value for one hour. During the test the receiver was in close proximity to the

Step-up transformer at the distance about 5 feet. During the runs with 50 kV

applied to bus bar corona occurred, which produced very strong sound. Mul-

tiple sensors have been located close to energized piece of bus bar to deter-

mine if their functions as well as performance of Receiver are affected by HV

corona.

Test Results

The effect of high Voltage and Corona in close proximity to the wireless sen-

sors has been found insignificant.

5.2. WTMS Validation Tests Provided by Testing Services

The following tests (Table 2) have been provided by Met Laboratories, Un-

derwriters Laboratories in Northbrook, IL and RF Laboratory of Square D in

Raleigh, NC. and Nemco USA, Inc. Test reports are available upon request.

FCC certification report has been received from Freshloc Technologies.

Table 2:

No. Test Standard, Level Test Lab Comments, Results

1UL Test / installation

Mesa Laboratories 90-0143-001 SCHNEIDER TEMPERATURE SENSOR User Manual 1

Freshloc Technologies SCHNEIDER TEMPERATURE SENSOR 1

User Manual

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