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vMonitor Wireless Monitoring

System
Installation, Maintenance and Troubleshooting
vMonitor

vMonitor Wireless System Installation, Maintenance and Troubleshooting Rev. 1.2 Page 1

Contents
Conventions Used in This Manual ............................................................................................................ 5
Special Instructions for Safe Use .............................................................................................................. 6
System Overview ..................................................................................................................................... 7
The iSens ................................................................................................................................................ 8
iSens Features ............................................................................................................................ 9
iSens Printed Circuit Board ......................................................................................................... 9
Radio Specifications...................................................................................................................10
Safety ........................................................................................................................................11
Shipping Instructions .................................................................................................................12
Default Shipping Configuration ..................................................................................................12
Handling and Storage Instructions .............................................................................................12
The i-Recv ..............................................................................................................................................13
Specification ..............................................................................................................................14
Power Requirements .................................................................................................................14
vMonitor User Interface.........................................................................................................................15
Set-Up ................................................................................................................................................... 16
Install the i-Config User Interface ...........................................................................................................16
Project Hierarchy ...................................................................................................................................16
Project Set-Up ...........................................................................................................................17
Create a new site.......................................................................................................................18
Add i-Recv .................................................................................................................................19
Add I-SENSs ...............................................................................................................................20
Configuring an i-Recv .............................................................................................................................21
Logical Configuration .................................................................................................................23
Logical i-Recv RS485 Serial Connection ......................................................................................26
Configuring iSens ...................................................................................................................................30
Configuration i-Sens procedure ..............................................................................................................33

Uploading Firmware to i-Sens ....................................................................................................33


Configure i-Sens ........................................................................................................................37
Configure the ID of iSens ...........................................................................................................39
Changing the Serial Number of iSens .........................................................................................42
Configure the Sleep Time of i-Sens ............................................................................................45
Changing the Report Factor of i-Sens .........................................................................................47
Reading Raw and EU values of i-Sens AI Channels for Voltage/Current Input .............................50
Configure i-Sens AI Channels for Raw values Calibration ............................................................53
Configure i-Sens AI Channels for Engineering Unit(EU)values Calibration ...................................58
Configure i-Sens AI Channels for Voltage Input-Output Calibration ............................................61
Configure i-Sens AI Channels for Current Input-Output Calibration ............................................64
Configure i-Sens Digital Input Channels .....................................................................................67
Configure i-Sens Digital Output Channels...................................................................................69
Configure i-Sens Analog Input Channels for Report By Exception(Alarms) ..................................73
Configure i-Sens Digital Input Channels for Report By Exception(Alarms) ...................................77
Jumper Settings for iSens Rev 0.0 ..............................................................................................81
Voltage Sensor Mode ................................................................................................................82
Current Loop Sensor Mode ........................................................................................................82
Configuring the iSens to support 4-20mA sensors ......................................................................83
4.0 Installing a iSens .............................................................................................................................. 84
Pre-installation ......................................................................................................................................84
Enclosure Mounting Configuration.........................................................................................................85
CONNECTING THE iSens Board to the Power Source ..................................................................86
Monitoring a Project ............................................................................................................................. 91
i-Recv Diagnostics Report .......................................................................................................................92
Network Info Tab.......................................................................................................................92
Triggered Calculations Tab.........................................................................................................92
Network Alarms Tab ..................................................................................................................92
WMP Msg Status .......................................................................................................................92
Network RF Status .....................................................................................................................92
Debug .......................................................................................................................................92
i-Report .....................................................................................................................................93

i-Chart .......................................................................................................................................94
Maintenance ......................................................................................................................................... 95
Troubleshooting Guide .......................................................................................................................... 96
New Firmware, i-Recv............................................................................................................................ 97
Checklist ................................................................................................................................................ 98
Mapping Register ................................................................................................................................ 100

Conventions Used in This Manual


This manual uses consistent conventions to help you identify items throughout the documentation. The
following table summarizes these conventions.

Convention

Use


Bold

Window and menu items


Technical terms, when introduced

Book and CD-ROM titles


Variable names and values
Emphasized words

File and folder names

Commands and code examples

Text you must type

Cross-reference jumps (in PDF)

Blue Text

URLs

SMALL CAPS

Keyboard button names, such as




Italics

Fixed Font

ENTER

The Note icon points out additional useful information. For example,
notes are generally used to point out links to additional information.

The Tip icon provides tips for performing specific operations. For
example, tips are generally used to point out shortcuts.

The Caution icon alerts you to all relevant safety points.

Special Instructions for Safe Use


Any disregard of these safety instructions may void the ATEX certification.

Do not install or service without a gas test.

Do not open when explosive gas is present.

This equipment is intended for use in a Zone I classified area. Use only in
accordance with ATEX specifications as listed in EN60079-15, EN500141998 and EN50018-2000.

Installation shall comply with instructions EN60079-14.

Use cable color coding in accordance with ATEX and NEC specifications.
Do not use a blue cable jacket (i).

System Overview
The vMonitor Wireless Monitoring System (VWMS) enables centralized monitoring of sensors placed
throughout a field of work. The system is based on three components including vMonitor Remote
Terminal Units (iSens), i-Recv and the i-Configx user interface. iSens gather information from sensors
and relay the information to the i-Recv, wirelessly. The i-Recv stores the information in pre-allocated
Modbus registers and serves as the communication hub. The i-Recv provides the stored information
directly to an Electronic Flow Computer, an RTU, a PLC or a process automation network using a
Modicon Modbus Protocol and an RS 485 serial interface. The i-Recv can also pass the information
stored in any of the Modbus registers to the 3 discrete analog and 2 discrete digital outputs.
Additionally, the i-Recv can also provide information directly to the system operator during normal
operation via the i-Config user interface, which is also used for system configuration, maintenance and
diagnostics.

The iSens
The iSens is a remote data transmitter. It mounts in the field, gathers sensor data, packetizes the
information and transmits it using a ZigBee spread spectrum radio. The radios comply with FCC part
15.247 regulations, and operate in either the 900 MHz or 2.4 GHz range, depending on the option
ordered. This sensor data message will be broadcast to an i-Recv and will be stored in pre-assigned
Modbus registers. The data collected from the sensors can be replicated on the i-Recvs discrete
outputs or it can be communicated from the Modbus registers over an RS485 connection to an attached
Flow Computer, RTU or PLC.
iSens are designed to operate on 12 volts which can be supplied by the included battery or by an
external power supply. In its standard configuration, safe, multi-year battery life can be expected.
The iSens will power sensors requiring a 10 to 15 volt supply. Sensors are connected by means of
terminal blocks.
The iSens powers up at a user determined interval, and after a brief settling period, samples the sensor
outputs.
Each iSens has a unique ID and is configured to work with a specific i-Recv, based on its unique ID.
Installation of the i-Recv must be in accordance with the instructions in this manual to ensure
conformance to UL, ATEX and FCC standards. Deviations from these instructions may compromise
conformance and safety.

iSens Features

Industry standard micro-controller


12 Volt battery standard, user supplied external 6 to 12VDC supply optional
Analog input channels for voltage or current sensors
10V and 15V supply available to power sensors
When supporting mA sensors, the ISENS can provide a regulated voltage source of 6.67v, 10v or
15v and can provide 200mA or 150mA to power sensors, respectively.
Two Opto-Isolated 3-24 volt, AC or DC digital inputs
Two hardware interrupts
One hardware interrupt input
Internal temperature and battery monitoring
Two Digital Outputs, one can support a solid state relay requiring up to 350mA
Low power and sleep operating modes
Option of a 900 MHz or 2.4 GHz Zigbee radio
Temperature range of 40C to +85C
Wake up timer can be programmed to operate from 0.008 seconds to 18 hours
RS232 Interface allows serial connection with a computer for configuration and for updating
firmware

iSens Printed Circuit Board

RS 232
Interface

Power

Analog I/O

Radio Specifications

900MHz

2.4GHz

Performance
Indoor/Urban Range w/2.1
Up to 1500 ft
dipole antenna
Outdoor RF line-of-sigh range
Up to 2 miles
(w/2.1 dB dipole antenna)
Outdoor RF line-of-sight
Up to 5 miles
Range w/ high-gain antenna
Transmit Power Output
100 mW (20 dBm)
Interface Data Rate (software
110-57600 bps
selectable)
(including nonstandard baud rates)
Throughput Data Rate
9,600
19,200 bps
bps
RF Data Rate
10,000
20,000 bps
bps
Receiver Sensitivity
-110
-107 dBm
dBm

Performance
Indoor/Urban Range w/2.1
Up to 600 ft
dipole antenna
Outdoor RF line-of-sight Range
Up to 1 mile
(w/2.1 dB dipole antenna
Outdoor RF line-of-sight Range
Up to 3 miles
w/ high-gain antenna
Transmit Power Output
50 mW (17 dBm)
Interface Data Rate (software
110-57600 bps
selectable)
(including nonstandard baud rates)
Throughput Data Rate
9,600
19,200
bps
bps
RF Data Rate
10,000
20,000
bps
bps
Receiver Sensitivity
-105
-102
dBm
dBm

Power Requirements

Power Requirements
Supply Voltage
5V ( 0.25V) regulated
Receive Current
80 mA
Transmit Current
150 mA
Power-Down Current
< 26 A

Supply Voltage
Receive Current
Transmit Current
Power-Down Current

5V ( 0.25V) regulated
50 mA
140 mA
< 26 A

General
1.600 x 2.825 x 0.350
(4.06 cm x 7.18 cm x 0.89 cm)
0.8 oz (24 g)
0-70 C (Commercial) or
-40 to 85 C (Industrial)
RPSMA, MMCX, or Wire
Antenna

Dimensions
Weight
Operating
Temperature
Antenna
Options

Networking and Security


Operating Frequency
ISM 902-928 MHz
Supported Network
Peer-to-Peer (no master/slave
Topologies
dependencies), point to point,
point to multi-point, multi-drop
Number of Channels 7 Frequency Hopping Channels
(software selectable)
Network Filtration
VID, Channel, Destination
Layer
Address
Agency Approvals
FCC Part 15.247
Industry Canada (IC)

OUR9XSTREAM
4214A-9XSTREAM

Dimensions
Weight
Operating
Temperature
Antenna
Options

General
1.600 x 2.825 x 0.350
(4.06 cm x 7.18 cm x 0.89 cm)
0.8 oz (24 g)
0-70 C (Commercial) or
-40 to 85 C (Industrial)
RPSMA, MMCX, or Wire Antenna

Networking and Security


Operating Frequency
ISM 2.4000-2.4835 GHz
Supported Network
Peer-to-Peer (no master/slave
Topologies
dependencies), point to point,
point to multi-point, multi-drop
Number of Channels 7 Frequency Hopping Channels
(software selectable)
Network Filtration
VID, Channel, Destination
Layer
Address
Agency Approvals
OUR-24XSTREAM
FCC Part 15.247
4214A 12008

10

Safety

WHILE HANDLING THE PRINTED TRANSMITTER CIRCUIT BOARD, ALWAYS USE


ELECTROSTATIC-FREE GLOVES AND CONNECTORS.

ALWAYS USE PROPER PROTECTIVE EQUIPMENT WHILE MAINTAINING THIS


DEVICE. EYE PROTECTION IS A MUST; THEREFORE, ALWAYS USE GOGGLES
WHILE MAINTAINING THIS DEVICE.

ENSURE THAT ALL WIRING ENTERS THE ISENS ENCLOSURE THROUGH THE
WEATHERPROOF CONDUIT AND CONDUIT FITTINGS, AS PER SECTION 501.4 OF
THE NATIONAL ELECTRIC CODE.

EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR NORMAL


OPERATION AND CAN NULLIFY THE CERTIFICATION FOR THE USE OF THIS
EQUIPMENT FOR CLASS 1, DIVISION 2 APPLICATIONS.

EXPLOSION HAZARD - DO NOT REPLACE BATTERIES UNLESS THE POWER TO


THE UNIT, AND ALL OTHER DEVICES CONNECTED TO IT, HAVE BEEN
SWITCHED OFF.

EXPLOSION HAZARD - DO NOT REPLACE THE BATTERIES IN A HAZARDOUS


AREA. MAKE SURE THE AREA IS UNCLASSIFIED AND KNOWN TO BE NONHAZARDOUS.

EXPLOSION HAZARD - THE SHORTENING OF THE TERMINALS OF ANY BATTERY


CAN RESULT IN AN EXPLOSION OF THE BATTERY. DO NOT PERMIT THE
TERMINALS OF THE PROVIDED BATTERY TO SHORTEN UNDER ANY
CIRCUMSTANCES.

ALWAYS MAKE SURE TO OBSERVE DC POLARITY BEFORE CONNECTING


EXTERNAL POWER SUPPLY TO THIS DEVICE.

EXPLOSION HAZARD - ALWAYS USE UL/CE APPROVED CLASS 2 POWER SUPPLY


AS AN EXTERNAL POWER SOURCE WHEN NEEDED, WITH NO EXCEPTIONS.

EXPLOSION HAZARD - DO NOT MAKE OR BREAK CIRCUIT CONNECTIONS WHILE


POWER IS ON UNLESS THE DEVICE IS IN A NON-HAZARDOUS AREA!

EXPLOSION HAZARD - ALWAYS TURN THE ON-OFF TOGGLE SWITCH TO THE


OFF POSITION AND DISCONNECT THE POWER SOURCE PRIOR TO ANY
MAINTENANCE WORK!

TO PREVENT STATIC ELECTRICAL SPARKS, ALWAYS CLEAN THE UNIT WITH A


DAMPENED CLOTH. NEVER USE DRY CLOTH.

11

Shipping Instructions
Prior to shipping, ensure that the POWER SWITCH SW1 on the
iSens board is in the OFF position.

Default Shipping Configuration


Prior to shipping, ensure that the SW1 switch on the ISENS is securely in the OFF
position.

The iSens is typically supplied with one UL approved battery pack. For shipping, the battery power
harness is disconnected from the power connector of the iSens main board to preserve battery life
during transit. The iSens will operate on power supplied by the battery pack or external DC line power.

Handling and Storage Instructions

The iSens transmitter unit is supplied with a NEMA 4X/7 explosion-proof die-cast
aluminum enclosure. Units with enclosures weigh approximately fourteen (14) pounds,
and do not need any special handling equipment.

While handling the printed transmitter circuit board, always use


electrostatic-free gloves and connectors.

The operating and storage temperature limits for the ISENS transmitter are shown below. Always
operate, test, handle, and store equipment within the specified limits:
Operating Temperature

-40 F to 185 F (-40 to 85 C)

Storage Temperature

-40F to 185 F (-40 to 85 C)

Operating Humidity

5 to 90% RH non-condensing

Electro-Static Discharge can damage the iSens boards and can cause complete or intermittent failure, observe ESD
prevention procedures when handling these boards. Also follow these ESD preventive tips when working with the boards:
1. Wear Electro-static gloves or wrist-straps, be sure that youre properly grounded, before handling the board.
2. When transporting the board, always have the board in a protective static-free bag or sleeve.
3. If the board is separate from the enclosure, always store the board in its protective static-free bag or sleeve.

12

The i-Recv
The i-Recv is the gateway between the process domain and the Flow Computer, PLC or RTU. The i-Recv
receives sensor data wirelessly from the iSens, acts as a data concentrator, and stores the data received
in Modbus registers. The i-Recv can provide the date to an attached Flow Computer, PLC or RTU over
discrete outputs and/or over a Modbus interface.
The i-Recv emulates an RTU with one side receiving data from the wireless sensor network and on the
other side presenting that data to the control system.
The i-Recv is located in a central position with respect to all associated iSens. Each standard i-Recv can
support up to 10 iSens, while the advanced i-RecvII can support up to 100 ISENS. Each i-Recv has a
unique i-Recv ID number, and will support all iSens which are configured to communicate with that
IRecv. All Data received from iSens which have a matching i-Recv number will be collected and mapped
to local Modbus registers. A SCADA system, Flow Computer, RTU or PLC can poll the designated registers
for each iSens over the RS-232/RS-485 serial port using Modbus RTU protocol.
The i-Recv is a logical database for all the associated iSens. The i-Recv will have a Modbus register set
which mirrors Modbus registers in each associated iSens. An i-Recv supporting 10 iSens will have 11
Modbus register sets; one for each iSenss data and engineering units and one for its own Modbus
register data.
In the standard configuration, iSens are configured to push samples to the i-Recv on a periodic or
interrupt driven basis. This configuration extends the battery life significantly. In the push mode, the
iSens will operate in battery conserving mode and will wake on the preconfigured interval, sample the
local sensors, accumulate the designated number of samples and push a message to the i-Recv when the
designated number of samples is collected. It may push a message sooner if transmission is triggered by
either a hardware interrupt, if configured by percentage changes or by reaching predetermined
minimum or maximum levels. When the iSens is in Poll mode, the unit is continuously powered,
sampling the I/O and waiting for the i-Recv to request data.
The i-Recv has built-in network diagnostics and using the i-Config, the operator can look at which iSens
are registered, the time the last message was received, and other information as described more fully in
the trouble shooting section of this manual.
The following sections of this manual describe how to create configuration files, how to upload
configurations to the i-Recv and iSens using the i-Config software and how to install the system. In the
event that i-Recv and iSens operation system updates are provided, instructions for uploading the new
operating systems are provided at the end of this document.

13

Specification

Industry Standard micro-controller


Supply voltage required: 7-34 VDC
Radio signal strength channel
Internal temperature channel
Two Opto-Isolated 3-24 volt, AC or DC digital inputs
Three analog 9 outputs than can emulate 0-5v or 4-20mA sensors
One RS232/RS485 serial interface port
Plug-in radio that can operate at a frequency of 900 MHz or 2.4 GHz
Temperature range of 40C to +80C

Power Requirements

The i-Recv has two power input terminals. They are both used in critical applications where the i-Recv
will be powered by a primary as well as a back-up power source. Either power source can be used as
the primary. The microcontroller will select the source operating at the higher voltage as the primary
supply.
The i-Recv will work on unregulated DC power from 7-34 VDC.
Current consumption of the i-Recv is:
Nominal Board current including radio in listen Mode: 72 mA
Power spike in transmit mode with all I/O active: 160 mA

14

vMonitor User Interface


The i-Config User Interface is a tool which allows the operator to configure iSens and i-Recv. It enables
basic data monitoring and provides access to network diagnostics one Project at a time.
At set up, the operator will create a Project. The i-Config can then be used to configure, monitor and
troubleshoot the project. Multiple projects can be created, saved, reopened, used and saved again.
Once a Project has been created, the i-Config will be used to upload the configurations into the
associated i-Recvs and iSens. Once the configurations have been uploaded into its i-Recvs and iSens, the
system can be bench tested before deployment to the field.

If you select a specific i-Recv in the Network and double click the icon in the Project Explorer Pane, a
tabular report will appear in the middle of the application screen displaying the i-Recv name and
showing basic data operational and diagnostics data for the associated iSens.

15

Set-Up
Set-up requires the creation of a Project and uploading the configurations into each i-Recv and iSens.
Installation requires configuring the jumpers and switches, mounting the iSens, attaching sensors and
power, configuring the jumpers and switches on the i-Recv, installing the i-Recv, and making a
connection to either the Flow Computer, RTU or PLC.

Install the i-Config User Interface


The i-Config is a configuration, monitoring and diagnostics tool. It allows the user to set up a Projects
hierarchy and configure the i-Recv and iSens used in the Project. The i-Config is provided in a self
extracting executable file. Download the latest version of the i-Config from the support website or copy
it from the CD provided. Double click on the file and follow the sequence of instructions to install the iConfig.

Project Hierarchy
To set up a Project the user begins with a Project name. Under the Project, individual sites each
representing a lease or field are established and assigned one i-Recv. Each standard i-Recv can support
up to 10 vMonitor Remote Devices such as the iSens.

16

Project Set-Up

Launch the i-Config User Interface

Click on File
Click on New Project
Enter a Project Name

17

Create a new site

Right Click on the name of your new project.


Click on add new
Slide over to Site
Click on Site
Enter a Site Name
Click Ok

Multiple sites can be created under your project.

18

Add i-Recv

Once the sites are created, a corresponding i-Recv must be created. There is a one-to-one relationship
between Sites and i-Recv.

Right click on a site


Slide to add new
Slide to i-Recv
Click on i-Recv
Enter a name for this i-Recv and check a numbered box to designate this i-Recvs Modbus slave
ID.
Click Ok

Each i-Recv must be given a unique Modbus slave ID.


The iSens which communicate with this i-Recv will automatically be given the same ID when their
configuration is uploaded to them.

19

Add I-SENSs

Once the sites i-Recvs are created, iSens can be added. Each standard i-Recv can support up to 10
iSens.

Right click on an i-Recv.


Slide to add new
Slide to iSens
Click on iSens
Enter a name for this ISENS and check a numbered box to designate this iSens Modbus slave ID.
Click Ok

Each iSens must be given a unique Modbus slave ID.

20

Configuring an i-Recv
Configuring an i-Recv includes setting up the hardware and uploading the configuration.
The default configuration for the i-Recv will include the latest revision of the firmware and certain
defaults including the following parameters:
Serial port Configuration: 9600, 8N & 1
MODBUS slave address: 1
Starting associated iSens address: 100
The serial port on the PC running the i-Config User Interface must be configured to match the above
communication parameters in order to upload the configuration to the i-Recv.

21

Jumper Settings for i-Recv Rev 0.0

All jumper and switch will be in the default settings as shown in the table below.
Jumper
Number

Setting

JP8
1-3 & 2-4
3-5 & 4-6

Selection of RS-232/RS-485 jumper


Enable RS-232 Communication
Enable RS-485 Communication

1-3 & 2-4


3-5 & 4-6

Selection of RS-232/RS-485 jumper


Enable RS-232 Communication
Enable RS-485 Communication

JP9

PSW1

PSW2

SW1
SW2
SW3
SW4

Description

1-ON
1-OFF

Set to ON (OPEN) to read AO Voltage on V01


Set to OFF (CLOSE) to read AO Current on Ai1

2-ON
2-OFF
1-ON
1-OFF

Set to ON (OPEN) to read AO Voltage on V02


Set to OFF (CLOSE) to read AO Current on Ai2
Set to ON (OPEN) to read AI Voltage on A1
Set to OFF (CLOSE) to read AI Current on A1

2-ON
2-OFF

Set to ON (OPEN) to read AI Voltage on A2


Set to OFF (CLOSE) to read AI Current on A2

3 -ON
3-OFF

Set to ON (OPEN) to read AI Voltage on A3


Set to OFF (CLOSE) to read AI Current on A3

4-ON
4-OFF

Set to ON (OPEN) to read AI Voltage on A4


Set to OFF (CLOSE) to read AI Current on A4

ON
OFF

Power Switch
10v/15v power to sensors (Push Towards SW1- 10V)
Restart board trigger
Reset/Download Switch

22

Logical Configuration

Select the i-Recv in the Project Explorer pane. Open the Properties pane following the directions below.
The Properties pane will show the properties of the selected i-Recv. Three tabs are visible: Basic,
Advanced and Wire Replacement. These tabs allow you to configure all of the i-Recvs parameters.

Click on View
Slide down to Properties
Click on Properties

The Basic tab allows you to configure communication parameters.


The Advanced tab enables calibration.
The Wire Replacement tab allows you to map data from any sensor on any supported iSens to any of the
discrete outputs on the i-Recv.

Enter values or accept the defaults for the configuration parameters.

23

Save the project changes by going to File > Save. After saving the project, all
network devices whose configurations have not yet been uploaded are so noted
with a red arrow indicator.

Connect the i-Recv to the configuration PC using the cable provided. The cable should be
connected to the correctly configured serial port on the PC and to JP7.
Connect JP1 or JP2 on the i-Recv to the local power supply.
Right click on the i-Recv you wish to configure
Slide to Upload Configuration
Click On Upload Configuration

If you receive the Session has expired message at this point, log in as the
Administrator on your PC and repeat Step 8.

The Connection Settings dialog box is displayed. This enables you to configure your PC to match the
configuration of the attached i-Config.

The Connection Type is set to RTU by default to configure the i-Recv when it is physically connected to
the configuration PC which is running the i-Config User Interface software.

Select the COM Port you are using on your PC


Use the default Baud Rate, 9600
Data Bit, Parity and Stop Bit should be set to 8, N and 1

24

Select the configuration to be uploaded

Click OK.

The configurations will be uploaded to the device.

25

Logical i-Recv RS485 Serial Connection

To poll the i-Recv on the RS485, change the jumpers on JP8 & JP9 as shown in the Figure below. Connect
the RS485+, RS485- and the Ground cables to COM2.

The iRecv RS485 serial port has the following configuration:


9600 baud
8 Data Bits
None Parity
1 Stop bit

Register Mapping for Raw Data


The i-Recv can support 10 i-Sens with ID 100-101. The Raw & Engineering Unit Datas of each of the iSens are mapped onto local registers of the i-Recv. The Raw Data for the three analog channels and the
battery channels can be polled on i-Recv registers:

26

[Slave ID 1]
[Input Register] [Display Type- Unsigned Integer]

27

Register Mapping for EU Data


[Slave ID 1]
[Input Register] [Display Type- Swapped Float]

28

Register Mapping for Signal Strength


The signal strength gives a measure of the quality of the wireless communication link between the iSens
and the iRecv. It has a range of -36db to 102db with -36db representing the best or highest signal
strength and -102db representing the lowest signal strength. This data can be read from the following
registers:
[Slave ID 1]
[Input Register] [Display Type- Unsigned Integer]

Register Mapping for Sleep Interval


The sleep time for each iSens can be changed through the iRecv. All the changes would be sent to the
iSens and would take effect only in the next communication. The sleep interval (in seconds) could be
changed through the following registers:
[Slave ID: ID of the iSens]
[Holding Register] [Display Type- Unsigned Integer]

29

Configuring iSens
Configuring an iSens includes setting up the hardware and uploading the configuration.
The default configuration for the iSens will include the latest revision of the firmware and certain
defaults including the following parameters:
Serial port Configuration: 9600, 8N & 1
MODBUS slave address: 1
Starting associated iSens address: 100
The serial port on the PC running the i-Config User Interface must be configured to match these
communication parameters in order to upload the configuration to the i-Recv.
Select the iSens in the Project Explorer pane. Open the Properties pane following the directions below.
The Properties pane will show the properties of the selected iSens. Three tabs are visible: Basic,
Advanced and Alarm. These tabs allow you to configure all of the iSenss parameters. Default
parameters will be displayed and can be changed or will be accepted as the default.

Click on View
Slide down to Properties
Click on Properties

The Basic tab allows you to configure communication parameters and timing as well as to select the
electrical characteristics of the 3 analog inputs, 3 digital inputs and 2 digital outputs.
The Advanced tab enables calibration.
The Alarm tab enables you to set minimum, maximum and percentage change that would trigger a
sample to be taken and sent.
Each of the 3 analog input channels can be separately configured to support a voltage out sensor or a
mA sensor. All channels will have the same sampling and transmission rates. Sampling rates can range
for 2 per second to one every 18 hours. Sampling and transmission frequency will impact battery life.
Each of an iSens 3 analog channels can provide power to a voltage out our current out sensors.
Alternatively, external power can be used. Low Power voltage sensors, powered by the iSens, are
typically selected because of the simplicity of the installation and the excellent battery life that can be
accomplished with appropriately set timers and triggers.
iSens will run on 6 to 12 VDC.

30

The iSens will go to sleep and wake-up at a programmed time interval and repeat the process. The red
LED will come on when the iSens is collecting and sending data and will go off when the iSens is in SLEEP
mode.
Reference - Basic Tab

The following table lists the configuration menu options and defaults under the Basic Tab.
Menu Option
General
Name
Primary Slave
Primary Slave
Message Setting
Sleep interval
Hour Time Offset to sync Reporting
Message Ack. Time out
Report Transmit Factor
Time Setting
Sensor Settling Time
Modem Settling Time (ms)
Delay Before Modem Shutdown
Delay between message Transmission
Delay Before Sleeping
Time Zone
Com Settings
Baud rate
Parity
Stop Bits
Data bits
Analog Input Channels
Channel 1
Channel 2
Channel 3
Channel 4
Digital Input Channels
Channel 1
Channel 2
Channel 3
Channel 4
Buffer Info
Analog Output Channels
Channel 1
Channel 2
Channel 3
Channel 4

Default Value

Slave ID: The i-Recv Modbus Slave ID


Operation Mode: The units mode of operation: Battery Conserving Sleep or Continuously Powered

31

Reference - Advanced Tab


The following table lists the configuration menu options and defaults on the Advanced Tab.
Menu Option
Channel Calibration
Channel 1
Smoothing Factor
Resistor Value
Raw Min count
Raw Max count
Flow Min count
Flow Max count
Calibration Low count
Calibration High count
Engineering Min.
Engineering Max
Channel 2
Channel 3
Channel 4
AO Calibration
Coefficient Factor
Constant

Default Value

Alarm Tab
The following table lists the configuration menu options and defaults on the Alarm Tab.
Menu Option
AI Channel Alarms
Channel 1
Raw Count Min (0 No Alarm)
Raw Count Max (0 No Alarm)
Percent Change
Channel 2
Channel 3
Channel 4

Default Value

32

Configuration i-Sens procedure

Uploading Firmware to i-Sens

Firmware can be uploaded to i-Sens by either I-CONFIG or WSD (Windows Serial


Downloader).

A. Through ICONFIG
The default configuration of the i-Sens will include the latest revision of the firmware and
some other parameters.
In case if you want a particular firmware to be loaded / reloaded the firmware in the i-Sens then :
Download the program/firmware. This requires a three stage process, with the first two
stages used to prepare the board for downloading the firmware. This involves resetting the
controller on the board and installing the serial number of the board. The final stage is
downloading the actual firmware.
Step 1: Power up i-Sens. Connect the Serial Cable (RS-232) to the serial port of i-Sens
and your PCs COM port.

Note 1: Make sure that the 1st switch of the PSW1 block (near to serial port) on i-Sens is
not pushed towards Open.
Now the i-Sens is in Configuration Mode.

33

Step 2: To reset controller, hold SW3 and turn SW1 OFF and ON, then release SW3.

Step 3:

Open ICONFIG, and load the project folder (File- Load Project).

Step 4:

Right-Click on the iSens and select the Upload Firmware option.

Step 5:

Open the folder containing the latest firmware and select the iSens.HEX and
click Open.

Step 6:

Select the COM port that corresponds to your computer port and click OK.

Step 7:

It will display OK. You have completed the download of the firmware.

Step 8:

If you want to check firmware on ICONFIG, you have to double click on iSens
again to see the changes.
34

Step 9: It will be shown as tabs in the ICONFIG main window. Connect using the green
button as shown before.
Step 10: i-Sens is now ready to be configured.
You can also view the firmware version of i-Sens on HyperTerminal.
Step 11: Connect to HyperTerminal and turn the board OFF and ON to reboot the
controller.
Step 12: HyperTerminal will display the version number of the firmware and it will say
configuration loaded ok. Disconnect from HyperTerminal.
Note 2: Turn the 1st switch of the PSW1 block on i-Sens to Open position after you upload any
firmware in order for the i-Sens to communicate with the iRecv.

B. Through Windows Serial Downloader (WSD)


WSD is a tool for downloading firmware or to reset boards.
Step 1: Connect the Serial Cable (RS-232) to the serial port of i-Sens and your PCs COM
port.
Note 1: Make sure that the 1st switch of the PSW1 block (near to serial port) on i-Sens is not
pushed towards Open.

Step 2: Click on the Configuration button, and select the appropriate Port. Select
correct options for Erase Mode, Download Mode. Check the box for Prompt
me for files when downloading. Then Click OK.

35

Step 3: Reset i-Sens controller by holding SW3 and turn SW1 OFF and ON and release
SW3.
Step 4: Click the Reset button on WSD.It will show you the message,Reset complete.

Step 5: Click on Download button and a new window will pop-up to select the firmware
file you want to upload to i-Sens.
Step 6: Select the file and Open it. The code will be loaded into the i-Sens controller
and the message Download successful will show.
Then the i-Sens is ready to be configured.
Step 7: In ModBus Poll, check the firmware of the i-Sens, poll Input Registers: 4 -5
(Float Inverse-Data type) with i-Sens ID=245.
Note 2: In Configuration mode, i-Sens ID=245.

36

Configure i-Sens

Step 1: In ICONFIG, select the i-Sens and click on View.


Step 2:

Click on Properties

Step 3: The Basic tab allows you to configure communication parameters, timing and to
select the electrical characteristics of the 3 analog inputs, 3 digital inputs and 2
analog outputs.

Step 4:

The Advanced tab enables calibration.

Step 5:

The Alarm tab enables you to set minimum, maximum and percentage change
that would trigger a sample to be taken and sent.

37

Step 6: Sampling rates can range from 2 per second to one every 18 hours. Sampling
and transmission frequency impacts battery life.
Step 7: Each of the i-Sens 3 analog channels can provide power to a Voltage out or
current out sensors, alternatively external power can be used.
Step 8: The i-Sens will go to sleep and wake-up at a programmed time interval and
repeat the process.
Step 9: The red LED will be ON when the i-Sens collects and sends data and will go
OFF when the i-Sens is in SLEEP mode.

Basic Operation
Turning the device ON with the jumper switch JP12 causes the following actions:
1) The device is powered and booted up as evidenced by the "VCC Red LED.
2) The device then goes into the data acquisition mode, where the sensors are
powered and the inputs are sampled.
3) The transceiver then transmits data to the Gateway/Data Concentrator.
4) The device goes into power-saving mode. The Red LED is now off. The unit is
now in sleep mode.
5) Once the unit comes out of sleep mode after the specified interval, the unit will
38

follow steps 2 to 4.
6) The unit can be forced to go into a transmit/active mode using the push button
switch SW4.
Caution: When the safety switch is turned off, external power is removed
or the battery is disconnected, the device ceases to operate. When
power is restored, normal operation is immediately resumed. No reprogramming is required. Any accidental power-cuts during the first three
steps may cause corruption of the iSens firmware. If external power is
supplied, the battery will serve as back-up and power the device until
power can be restored.

Configure the ID of iSens

We can configure the iSens parameters through ICONFIG or through corresponding Mapping
Registers of iSens using ModBus Poll.
By default, i-Sens Slave ID=100.

A. Through ICONFIG
Step 1: In ICONFIG, open the project and click on the iSens .It will show you the
Properties window. Click on the Basic tab.
Step 2: Slide onto Slave ID. Select it and pick any ID from the list and then click OK.
Step 3: Save it before you upload the settings to iSens. Before uploading the settings,
keep the iSens in Configuration Mode.
Note 1: Connect the Serial Cable (RS-232) to the serial port of iSens and your PCs COM port.

Make sure that the 1st switch of the PSW1 block (near to serial port) on iSens is not pushed
towards Open.

39

Step 4: To upload the configuration, Right click on iSens and select upload
configuration via iSens.
Step 5: Perform the appropriate connection settings.
Step 6: Select the tabs values you want to upload. You can choose what tabs to configure
and upload.

Step 7: Once selected, all or partial, press OK to upload the configuration.


Step 8: After uploading configuration, Right click on iSens and select Properties.
Step 9: Click on Basic Tab and you can see the new Slave ID.
40

B. Through ModBus Poll

Step 1: Keep the i-Sens in Configuration Mode.


Step 2: Open a new MB Poll window with iSens ID=245.
Poll Holding Register: 123(Set new Slave ID) and write the ID which you want to keep for iSens.
Step 3: Click on the Send button to write it on the i-Sens controller.
Note 1: In Configuration Mode, iSens ID is 245.
Note 2: Data type of this register must be an Un-signed Integer.

41

When iSens wakes up the next time, it will register with the new ID.
Step 4: Poll Input Register: 07(Un-signed Integer) with iSens ID=245 and you can see
the current Slave ID after changing.
When iSens Communicates with iRecv using Radios, you can still poll the above registers with iSens Slave ID.

Changing the Serial Number of iSens

A. Through ICONFIG
Step 1: Before entering the Serial Number through ICONFIG and uploading the settings,
keep the iSens in Configuration Mode.
Step 2: In ICONFIG, open the project and Right Click on the iSens.
Step 3: Select Set Points and slide onto i-Sens ID. Select it.

42

Step 4: Enter the password and the serial number. Click OK and it will be directly written
to the i-Sens.
Step 5: After writing new serial number, do settings for RS-232 Communication with
iRecv:
1) Turn the 1st switch of the PSW1 block on i-Sens to Open position and do the
settings for communication with iRecv.
2) Connect the Serial Cable to your PCs COM port and 2nd port of iRecv
(TX2+,RX2-,G). Close pins 1-2&3-4 of JP8&JP9 using jumpers as shown on pg.44

3) Insert the appropriate Radios on iRecv and iSens and Power ON both.
Note 1: It is better to Turn ON i-Sens after iRecv for better registration of i-Sens on iRecv.
43

The default configuration of the iRecv will include the latest revision of the firmware and
certain defaults including the following parameters:
a) Serial port Configuration:
Baud Rate-9600
Bits-8
Parity-None
Stop Bits-1
b)

ModBus slave address: 1

c)

Starting associated iSens address: 100.

Step 6: If you want to check on ICONFIG, you have to double click on iRecv and iSens
tags again to see the changes.
Step 7: It will be shown as tabs in the ICONFIG main window. Connect using the green
button, as shown before. You can see the new Serial Number of iSens as shown.

B. Through Modbus Poll


Step 1: Keep the i-Sens in Configuration Mode.
Step 2: Open a new MB Poll window with i-Sens ID=245.

44

Poll Holding Register: 141-142(Password Value)


Poll Holding Register: 143-144(New Hardware Serial Number).
Step 3: Enter Password and Serial Number using multiple register writing. Click on the
Send button to write the values into the i-Sens controller.

Note 1: In Configuration Mode, i-Sens ID will be 245.


Note 2: Data type of these registers must be Long Inverse.
Step 4: Poll Input Registers: 02 -03 (Long Inverse) with i-Sens ID=245 and you can will
the new Serial Number right away.
When i-Sens Communicates with iRecv using Radios, you can still poll the above registers with
i-Sens Slave ID.

Configure the Sleep Time of i-Sens

A. Through ICONFIG
Step 1: In ICONFIG, open the project and Click on the i-Sens. It will show you the
Properties window. Click on the Basic tab.
Step 2: Slide onto Sample Every (sec) option. Select and enter the time in seconds.

45

Step 3: Save it before you upload the settings to i-Sens. Before uploading the settings,
keep the i-Sens in Configuration Mode.
Step 4: To upload the configuration, Right click on i-Sens and select upload
configuration via i-Sens.
Step 5: Select the tabs values you want to upload. You can choose which tabs to
configure and upload.
Step 6: Once selected, all or partial, press OK to upload the configuration.
You can check the new sleep time using ModBus Poll.
Step 7: Open a new MB Poll window with i-Sens ID= 245.
Poll Holding Registers: 03 (Un-signed Integer) and you can see the new sleep interval of i-Sens.

B. Through Modbus Poll

Step 1: Keep the i-Sens in Configuration Mode.


Step 2: Open a new MB Poll window with i-Sens ID=245.
46

Poll Holding Register: 03(Sleep Interval ) and write the time in seconds.
Step 3: Click on Send button to write it on the i-Sens s controller.
Note 1: In Configuration Mode, i-Sens ID is 245.
Note 2: Data type of this register must be Un-signed Integer.
When i-Sens wakes up the next time, it will start reporting in the new Report Transmit Time.
Step 3: Poll the same Holding Register: 03 (Un-signed Integer) with i-Sens ID=245 and
you can see the new Report Time.
When i-Sens communicates with iRecv using Radios, you can still poll the above register with iSens Slave ID.

Changing the Report Factor of i-Sens

A. Through ICONFIG
Step 1: In ICONFIG, open the project and click on the i-Sens. It will show you the Properties
window. Click on the Basic Tab.
Step 2: Slide onto Report Factor (sec) option. Click on that and enter the time in seconds.

47

Step 3: Save before you upload the settings to i-Sens. Before uploading the settings, keep the iSens in Configuration Mode.
Step 4. To upload the configuration, Right click on i-Sens and select upload configuration via
i-Sens.
Step 5. Select the tabs values you want to upload. You can choose what tabs to configure and
upload.
Step 6. Once selected, all or partial, press OK to upload the configuration.
You can check the new Report factor using ModBus Poll.
Step 7: Open a new MB Poll window with i-Sens ID= 245.

Poll Holding Registers: 23 (Un-signed Integer) and you can see the new Report factor of i-Sens.

48

C. Through ModBus Poll (MB Poll)


Step 1 : Keep the i-Sens in Configuration Mode.
Step 2 : Open a new MB Poll window with i-Sens ID= 245.
Poll Holding Register: 23(Report Transmit Factor) and write the time in seconds.
Step 3: Click on the Send button to write it on the i-Sens controller.
Note 1: In Configuration Mode, i-Sens ID is 245.
Note 2: Data type of this register must be Un-signed Integer.
When i-Sens wakes up the next time, it will start reporting in the new Report Transmit Time.
Step 4: Poll the same Holding Register: 23(Un-signed Integer) with i-Sens ID=245 and
you can see the new Report Time.
When i-Sens Communicates with iRecv using Radios, you can still poll the above register
with i-Sens Slave ID.

49

Reading Raw and EU values of i-Sens AI Channels for Voltage/Current Input

A. Through ICONFIG

Step 1: In ICONFIG, open the project and Click on the i-Sens. It will show you the
Properties window. Click on the Basic Tab.
Step 2: Select Analog Input Channels and under that select Channel 1.
Step 3: Slide onto Voltage/Current. Select Voltage/Current as you need.
You can do the same settings for all 3 analog channels and also for the battery channel.
Step 4: Save before you upload the settings to i-Sens. Before uploading the settings, keep
the i-Sens in Configuration Mode.
Step 5: To upload the configuration, Right click on i-Sens and select upload
configuration via i-Sens.
Step 6: Select the tabs values you want to upload. You can choose what tabs to configure
and upload.
Step 7: Once selected, all or partial, press OK to upload the configuration.
Step 8: Give Inputs to the Analog Channels from source(Voltage/Current) through the
corresponding pins.
Note 1: Source +ve to AI+ of Channels.

Source ve to AI- of Channels.

Note 2: For Voltage Input, the switches of PSW2 block on i-Sens should be pushed towards
open position. For Current Input, make sure that switches of PSW2 block on i-Sens is not
pushed towards open position .
50

Step 9: After uploading configuration, do settings for RS-232 Communication with


iRecv :
1) Turn 1st switch of the PSW1 block on i-Sens to Open position and do the settings
for communication with iRecv.
2) Connect the Serial Cable to your PCs COM port and 2nd port of iRecv
(TX2+,RX2-,G).Close pins 1-2&3-4 of JP8&JP9 using jumpers as shown before.
3) Insert appropriate Radios on iRecv and i-Sens and Power ON both.
Note 1: It is better to Turn ON i-Sens after iRecv for better registration of i-Sens on iRecv.
Step 10: If you want to check on ICONFIG, double click on iRecv and i-Sens tags
again to see the changes.
Step 11: It will be shown as tabs in the ICONFIG main window. Connect using the
green button, as shown before. You can see the Raw and Engineering Unit
values for AI channels as shown below.

51

B. Through ModBus Poll

Step 1 : Keep the i-Sens in Configuration Mode.


Step 2 : Open a new MB Poll window with i-Sens ID= 245.
Poll Holding Register: 97-100(Analog Input Channels Type)
Default type is voltage for 3 analog channels and last one is battery.
Note 1: Type: 0- Inactive, 1-Current, 2-Voltage, 3-Battery, 4-Temp, 5-Humidity,6- RSSI.
Step 3: Enter values as you need for each type of channel. You can use multiple register
writing.
Step 4: Click on the Send button to write it into the i-Sens controller.
When i-Sens wakes up the next time, you can see the changes in the same Holding
Registers: 97 -100 (Un-signed Integer).
Step 5: Give Inputs on channels .
Poll Input Registers: 40 -43 (Raw count for 3 input channels and battery channel) with
i-Sens ID=245 and it will show you the values.
Note 2: Data type of these registers must be Un-signed Integer.
Step 6: Poll Input Registers: 52 -59 (EU for 3 input channels and battery channel) with
i-Sens ID=245 and it will show you the values.
Note 3: Data type of these registers must be Float Inverse.
When i-Sens Communicates with iRecv using Radios, you can still poll the above registers with
i-Sens Slave ID.

52

Configure i-Sens AI Channels for Raw values Calibration

Calibration is required only when the AI input is not in range of 1-5V/4-20mA.

A. Through ICONFIG

Step 1: In ICONFIG, open the project and Click on the i-Sens . It will show you the Properties
window. Click on the Advanced Tab.
Step 2: Select Channel Calibration and under Calibration Type slide onto Raw.
Step 3: Select Channel 1 and you will see four parameters. These parameters are available for all
3 Analog Channels and also for the Battery channel.
Step 4: Select the parameters you want to change and enter the values:
1) Smoothing Factor = 0
2) Resis Value = 2.604
Note 1: For precise results, Resis value=(250 ohms/ Measured resistance between AI +ve and
AI -ve )
3) Calib Low Count = 12840
4) Calib High Count = 64000

53

Step 5: Save before you upload the settings to i-Sens. Before uploading the settings, keep
the i-Sens in Configuration Mode.
Step 6. To upload the configuration Right click on i-Sens
configuration via i-Sens.

and select upload

Step 7. Select the tabs values you want to upload. You can choose what tabs to configure
and upload.
Step 8. Once selected, all or partial, press OK to upload the configuration.
Step 9: Give Inputs to the Analog Channels from source (Voltage/Current) through the
corresponding pins.
Note 2: Source +ve to AI+ of Channels.
Source ve to AI- of Channels.
Note 3: Depending on the Input type (Voltage/Current),keep the position of the switches of
PSW2 block.

54

Step 10: After uploading configuration, set the RS-232 Communication with iRecv :
1) Turn the 1st switch of the PSW1 block on i-Sens to Open position and
complete the settings for communication with iRecv.
2) Connect the Serial Cable to your PCs COM port and 2nd port iRecv
(TX2+,RX2-,G).Close pins 1-2&3-4 of JP8&JP9 using jumpers as shown
before.
3) Insert appropriate Radios on iRecv and i-Sens and Power ON both.
Note 4: It is better to Turn ON i-Sens after iRecv for better registration of i-Sens on iRecv.
Step 11: If you want to check on ICONFIG, double click on iRecv and i-Sens tags
to see the changes.
Step 12: It will be shown as tabs in the ICONFIG main window. Connect using the
green button, as shown before. You can see the results as in below figure.
Note 5: Calib Low and High Count varies for each channel.
Channel 2:
Calib Low Count= 12840
Calib High Count= 64000
Channel 3:
Calib Low Count= 13280
Calib High Count= 65535
Channel 4(Battery):
Resis Value = 1
Calib Low Count = 13280
Calib High Count= 65535
You can configure the 3 Analog Channels and the Battery Channel with specified Calibration
values through steps 3 -10.

55

B. Through ModBus Poll

Step 1 : Keep the i-Sens in Configuration Mode.


Step 2 : Open a new MB Poll window with i-Sens ID= 245.
Poll Holding Register: 145(Calibration Type)
Note 1: Type: 0- Raw Count,1- Current,2- Voltage.
Poll Holding Registers: 146 -149(Float Inverse) for Channel 1.
Step 3: Enter Raw Low=12840 in Register: 146 -147 and Raw High=64000 in
Register: 148 -149. You can use multiple register writing.
Step 4: Click on the Send button to write it into the i-Sens controller.
When i-Sens wakes up the next time, Analog channel 1 would have calibrated.
Step 5: Give Inputs on channels.
Poll Input Registers: 40 -43 (for 3 input channels and battery channel) with i-Sens
ID=245 and it will show you the Raw data on channels.

56

Note 2: Data type of these registers must be Un-signed Integer.


Step 6: You can write Raw Min and Raw Max into
Holding Registers: 150 -153 for Channel 2
Holding Registers: 154 -157 for Channel 3
Holding Registers: 158 -161 for Channel 4 (battery) and you can see the Raw
data on these channel registers.
Note 3: Data type of these registers must be Float Inverse.
When i-Sens Communicates with iRecv using Radios ,you can still poll the above registers
with i-Sens Slave ID.

57

Configure i-Sens AI Channels for Engineering Unit(EU)values Calibration

A. Through ICONFIG

Step 1: In ICONFIG, open the project and click on the i-Sens . It will show you the
Properties window. Click on the Advanced Tab.
Step 2: Select Engineering Units.
Step 3: Select Channel 1 and you will see two parameters. These parameters are available
for all 3 Analog Channels and also for Battery channel.
Step 4:

Enter the values for:


Engineering Min= 0
Engineering Max=1500

Step 5: Save before you upload the settings to i-Sens. Before uploading the settings, keep
the i-Sens in Configuration Mode.
Step 6: To upload the configuration, Right click on i-Sens and select upload
configuration via i-Sens.
Step 7: Select the tabs values you want to upload. You can choose what tabs to configure
and upload.
Step 8: Once selected, all or partial, press OK to upload the configuration.
Step 9:

Give Inputs to the Analog Channels from source (Voltage/Current) through the
corresponding pins as shown in the previous diagram.

Note 1: Source +ve to AI+ of Channels.


Source ve to AI- of Channels.
Note 2: Depending on the Input type(Voltage/Current),keep the position of the switches of PSW2
block.

58

Step 10:

After uploading configuration, do settings for RS-232 Communication with


iRecv :
1) Turn the 1st switch of the PSW1 block on i-Sens to Open position and
do the settings for communication with iRecv.
2) Connect the Serial Cable to your PCs COM port and 2nd port of
iRecv(TX2+,RX2-,G).Close pins 1-2&3-4 of JP8&JP9 using jumpers as
shown before.
3) Insert appropriate Radios on iRecv and i-Sens and Power ON both.

Note 3: It is better to Turn ON i-Sens after iRecv for better registration of i-Sens on iRecv.
Step 11:

If you want to check on ICONFIG, double click on iRecv and i-Sens tags again
to see the changes.

Step 12:

It will be shown as tabs in the ICONFIG main window. Connect using the green
button, as shown before.
Note 4: Calib Low and High Count varies for each channel. EU Low and
high Count depends on the sensor capacity.

59

Channel 2 and Channel 3:


Engineering Min=0
Engineering Max=1500
Channel 4(Battery):
Engineering Min=0
Engineering Max=20
You can configure the 3 Analog Channels and the Battery Channel with specified Calibration
values through steps 3 -10. You can also configure them together and then upload it to i-Sens at
once.

B. Through ModBus Poll

Step 1 : Keep the i-Sens in Configuration Mode.


Step 2 : Open a new MB Poll window with i-Sens ID= 245.
Poll Holding Registers: 31 -34(EU for Channel 1).
Note 1: Data type of these registers must be Float Inverse.
Step 3:

Enter EU Low=0 in Register: 31-32 and EU Max=1500 in Register: 33 -34.


You can use multiple register writing.

Step 4: Click on the Send button to write it into the i-Sens controller.

When i-Sens wakes up the next time, Analog channel 1 would have calibrated.
Step 5:

Give Inputs on channels.

60

Poll Input Registers: 52 -59 (for 3 input channels and battery channel) and it will show
you the EU data on channels.
Note 2: Data type of these registers must be Float Inverse.

Step 6: You can write EU Min and EU Max into


Holding Registers: 41-44 for Channel 2
Holding Registers: 51-54 for Channel 3
Holding Registers: 61-64 for Channel 4(battery) and you can see the EU data on
channel registers.
When i-Sens Communicates with iRecv using Radios, you can still poll the above registers
with i-Sens Slave ID.

Configure i-Sens AI Channels for Voltage Input-Output Calibration

A. Through ICONFIG

Step 1:

Step 2:

In ICONFIG, open the project and Click on the i-Sens . It will show you the
Properties window.
Click on the Advanced Tab. Select Channel Calibration and select Raw.
Note 1: Never change the calibration type to voltage/current.

61

Step 3:

You can repeat the steps 3-8 for configuring AI channels for Raw/EU as per your
need or both.

Step 4:

After uploading configuration, do the settings for RS-232 Communication with


iRecv :
1) Turn the 1st switch of the PSW1 block on i-Sens to Open position and set
communication with iRecv.
2) Connect the Serial Cable to your PCs COM port and 2nd port of iRecv
(TX2+,RX2-,G).Close pins 1-2&3-4 of JP8&JP9 using jumpers as shown
before.
3) Insert appropriate Radios on iRecv and i-Sens and Power ON both.

Note 2: It is better to Turn ON i-Sens after iRecv for better registration of i-Sens on iRecv.
Step 5:

Before giving the inputs in the AI Channels, make sure that the switches of the
PSW2 block on i-Sens are pushed towards an open position. It is for Voltage
Input-Output.

Step 6:

If you want to check on ICONFIG, double click on iRecv and i-Sens tags again
to see the changes.

Step 7:

It will be shown as tabs in the ICONFIG main window. Connect using the green
button, as shown before. You can also see the AI Channel values as shown
previously.

B. Through ModBus Poll

Step 1 :

Keep the i-Sens in Configuration Mode.

Step 2 :

Open a new MB Poll window with i-Sens ID= 245.


62

Poll Holding Registers: 97-100 (Un-signed Integer) for all AI Channels. Default value is
Voltage for all 3 AIs.
Poll Holding Register: 145 (Calibration Type). Enter 2 for voltage.
Note 1: Type: 0- Raw Count,1- Current,2- Voltage.

Step 3:

Enter the values for all channels. You can use multiple register writing.
Note 2: Type:0- Inactive,1- Current,2- Voltage, 3- Battery,4Temperature,5- Humidity.

Step 4:

Click on the Send button to write it into the i-Sens controller. Give Voltage Inputs
on AI Channels.
When i-Sens wake up the next time, you can see the changes in the same Holding
Registers: 97 -100 (Un-signed Integer) for all AI Channels.

Step 5:

Give Inputs on channels.


Poll Input Registers: 40 -43 (Raw data) or Input Registers: 52 -59 (EU data)
for the corresponding input values.
When i-Sens Communicates with iRecv using Radios, you can still poll the above
registers with i-Sens Slave ID

63

Configure i-Sens AI Channels for Current Input-Output Calibration

A. Through ICONFIG

Step 1:

In ICONFIG, open the project and Click on the i-Sens. It will show you the
Properties window.

Step 2:

Click on the Advanced Tab. Select Channel Calibration and select Raw.

Step 3:

You can repeat steps 3-8 for configuring AI channels for Raw/EU per your need
or both.

Step 4:

After uploading configuration, do settings for RS-232 Communication with


iRecv:
1)

Turn the 1st switch of the PSW1 block on i-Sens to Open position and
do the settings for communication with iRecv.

2)

Connect the Serial Cable to your PCs COM port and 2nd port of
iRecv(TX2+,RX2-,G).Close pins 1-2&3-4 of JP8&JP9 using jumpers as
shown before.

3)

Insert appropriate Radios on iRecv and i-Sens and Power ON both.

64

Note 1: It is better to Turn ON i-Sens after iRecv for better registration of i-Sens on iRecv.
Note 2: For Current Input-Output, make sure that Resis Value= 2.604 (For precise results, calculate
Resis value). For all 3 Analog Channels and for Battery it should be 1.0.

Step 5:

Before giving the inputs in AI Channels, make sure that switches of PSW2 block
on i-Sens is not pushed towards open position. It is for Current Input-Output.

Step 6:

If you want to check on ICONFIG, double click on iRecv and i-Sens tags again
to see the changes.

Step 7:

It will be shown as tabs in the ICONFIG main window. Connect using the green
button, as shown before. You can see the AI channel values as shown previously.

B. Through ModBus Poll

Step 1 :

Keep the i-Sens in Configuration Mode.

Step 2 :

Open a new MB Poll window with i-Sens ID= 245.

Poll Holding Registers: 97-100 (Un-signed Integer) for all AI Channels.


Default value is Voltage for all 3 AIs.
Note 1: Type:0- Inactive,1- Current,2- Voltage,
3- Battery,4-Temperature,5- Humidity,6-RSSI.
Poll Holding Register: 145 (Calibration Type). Enter 1 for current.

65

Note2: Type: 0- Raw Count,1- Current,2- Voltage.


Step 3:

Enter the values for all channels. You can use multiple register writing.

Step 4:

Click on the Send button to write it into the i-Sens controller. Give the Current
Inputs on AI Channels.
When i-Sens wakes up next time, you can see the changes in the same Holding
Registers: 97-100(for all AI Channels)
Note 3: The Data type of these registers must be an Un-signed Integer.

Step 5:

Give inputs on channels.


Poll Input Registers: 40-43 (Raw data) or Input Registers: 52 -59 (EU data) for
the corresponding input values.
When i-Sens Communicates with iRecv using Radios, you can still poll the above
registers with i-Sens Slave ID.

66

Configure i-Sens Digital Input Channels

A. Through ICONFIG

Step 1:

In ICONFIG, open the project and Click on the i-Sens. It will show you the
Properties window. Click on Basic Tab.

Step 2:

Select Digital Input Channels and select Channel 1.

Step 3:

Slide onto Digital from list and select it. You can do the same for Channel 2 also.

Step 4:

Save before you upload the settings to i-Sens. Before uploading the settings, keep
the i-Sens in Configuration Mode.

Step 5:

To upload the configuration Right click on i-Sens and select upload


configuration via i-Sens.

Step 6:

Select the tabs values you want to upload. You can choose what tabs to configure
and upload.

Step 7:

Once selected, all or partial, press OK to upload the configuration.

67

Step 8:

After uploading configuration, do the settings for RS-232 Communication with


iRecv :
1) Turn 1st switch of the PSW1 block on i-Sens to Open position and do
the settings for communication with iRecv.
2) Connect the Serial Cable to your PCs COM port and 2nd port of iRecv
(TX2+,RX2-,G).Close pins 1-2&3-4 of JP8&JP9 using jumpers as
shown before.
3) Insert appropriate Radios on iRecv and i-Sens and Power ON both.

Note 1: It is better to Turn ON i-Sens after iRecv for better registration of i-Sens on iRecv.
Step 9:

Give Inputs on Digital Input Channels.


Note 2: Source +ve to DI+ve of Channels.
Source ve to DI-ve of Channels.

Step 10:

If you want to check on ICONFIG, double click on iRecv and i-Sens tags again to see
the changes.

Step 11:

It will be shown as tabs in the ICONFIG main window. Connect using the green button,
as shown before.

B. Through ModBus Poll

Step 1 :

Keep the i-Sens in Configuration Mode.

68

Step 2 :

Open a new MB Poll window with i-Sens ID= 245.


Poll Holding Registers : 101-102(Un-signed Integer) for both DI Channels.
Default value is Inactive for both DIs.
Note 1: Type: 0- Digital,1- Pulse Counter,2- Pulse Accumulation,3-

Inactive.
Step 3:

Enter the values for both channels. You can use multiple register writing.

Step 4:

Click on Send button to write it into the i-Sens controller.


When i-Sens wakes up next time, you can see the changes in the same Holding
Registers: 101 -102(for both DI Channels)
Note 2: Data type of these registers must be Un-signed Integer.

Step 5:

Give Inputs on DI Channels.


Poll Input Status:1-2 (Un-signed Integer) with i-Sens ID=245 for the
corresponding input values.

Note 3: For Low input, the status will be 0.


For High input, the status will be 1.

When i-Sens Communicates with iRecv using Radios, you can still poll the above registers with
i-Sens Slave ID.

Configure i-Sens Digital Output Channels

Digital Output Channels can be used for Well Shut In function.

69

A. Through ICONFIG

Step 1:

Step 2:

In ICONFIG, open the project and Click on the i-Sens. It will show you the
Properties window. Click on Advanced Tab.
Select Well Shut In and enter the parameters (as per your need) for:
1) Num. Missed Ack Message = 5 (the No. of failed attempts i-Sens makes to
communicate with iRecv)
2) Digital Output Channel= 1(DO Channel which is used to Shut In the Well
head, when there is a communication problem).

Note 1: Choose any of the Digital Output channel for this. This will create a digital HIGH signal (just for a
second)which will close the well head when there is any improper communication between i-Sens and
iRecv.
You can extend the Digital Output status by changing the Digital Out Setting time of i-Sens.
Holding Register: 14 in milliseconds.
Default is 500 milliseconds.

70

In ICONFIG, open the project and click on the i-Sens. It will show you the
Properties window. Click on Basic Tab.

Step 3:

Step 4:

Select Time Setting and slide onto Digital Out Setting Time. Select it and enter
the time in milliseconds.

Step 5:

Save and upload the settings to i-Sens . Before upload the settings keep the iSens in Configuration Mode.

Step 6:

To upload the configuration, Right click on i-Sens and select upload


configuration via i-Sens.

Step 7:

Select the tabs values you want to upload. You can choose what tabs to configure
and upload.

Step 8:

Once selected, all or partial, press OK to upload the configuration.

Step 9: After uploading configuration do settings for RS-232 Communication with iRecv:
1) Turn 1st switch of the PSW1 block on i-Sens to Open position and do
the settings for communication with iRecv.
2) Connect the Serial Cable to your PCs COM port and 2nd port of
iRecv(TX2+,RX2-,G).Close pins 1-2&3-4 of JP8&JP9 using jumpers as
shown before.
3) Insert appropriate Radios on iRecv and i-Sens and Power ON both.
Note 2: It is better to Turn ON i-Sens after iRecv for better registration of i-Sens on iRecv.

Manual control of Well Shut In without waiting for the Missed Ack number.
1) Right Click on i-Sens and slide onto Set Points. Select Digital Out.
2) Select Digital Out-1 and Turn it ON.
3) Click OK and it will be written to i-Sens controller as a message sent
by the iRecv, when the i-Sens wakes up next time.
Note 3: Only Digital Output functionality can be written to i-Sens controller without putting it into
configuration mode.

71

B. Through ModBus Poll

Step 1:
Step 2:

Keep the i-Sens in Configuration Mode.


Open a new MB Poll window with i-Sens ID= 245.
Poll Holding Registers: 130 (Number of Missed Acknowledge Message)
Poll Holding Register: 131 (Digital Output Channel for Well Shut In).
Note 1: Data type of these registers must be Unsigned Integer.

Step 3:

Enter the values for both channels. You can use multiple register writing.

Step 4:

Click on the Send button to write it into the i-Senss controller.


When i-Sens wakes up next time, you will see the changes
Holding Registers: 130 -131

72

Step 5: Poll Coil Status: 1-2 (Un-signed Integer) and when there is a missed
communication Coil Status 2 will give a HIGH signal.
You can extend the DO status by writing specified time written in milliseconds
on Holding Register: 14(Un-signed Integer)
When i-Sens Communicates with iRecv using Radios, you can still poll the above
registers with i-Sens Slave ID.

Configure i-Sens Analog Input Channels for Report By Exception(Alarms)

The Report By Exception is similar to the Alarms feature. This does not set any Flags on i-Sens but
sets Status flags on iRecv for changes in input values. If it is activated for any Channel, i-Sens
sends messages to iRecv when there is any change in Analog input values.
A. Through ICONFIG

Step 1:

In ICONFIG, open the project and Click on the i-Sens. It will show you the
Properties window. Click on the Alarms Tab.

73

Step 2:
Step 3:

Select AI Channel Alarms. Click on Channel 1.


Enter the values as you need for parameters:
1) Raw Count Min= 11500
2) Raw Count Max= 55000
3) Percentage Change= 2

Step 4:

Save and upload the settings to i-Sens. Before uploading the settings keep the iSens in Configuration Mode.

Step 5: To upload the configuration, Right click on i-Sens and select upload
configuration via i-Sens.
Step 6: Select the tabs values you want to upload. You can choose what tabs to configure
and upload.
Step 7:

Once selected, all or partial, press OK to upload the configuration.

Step 8:

After uploading configuration do settings for RS-232 Communication with


iRecv :

74

1) Turn the 1st switch of the PSW1 block on i-Sens to Open position and
do the settings for communication with iRecv.
2) Connect the Serial Cable to your PCs COM port and 2nd port of iRecv
(TX2+,RX2-,G).Close pins 1-2&3-4 of JP8&JP9 using jumpers as
shown before.
3) Insert appropriate Radios on iRecv and i-Sens and Power ON both.
Note 1: It is better to Turn ON i-Sens after iRecv for better registration of i-Sens on iRecv.

Step 9:

Give Inputs on Analog Input Channels of i-Sens.


Note 2: Source +ve to AI +ve of Channels.
Source ve to AI -ve of Channels.

Step 10: Connect to iRecv in ICONFIG. In iRecv communication window click on the
Network Alarms Tab and there you can find if any Channel Alarm is ON or not
and which i-Sens created it.
Step 11: To clear the Alarms, Right Click on iRecv and select Set Points. Slide onto
Clear Alarms. Once you clear the alarm, Channel Alarm will show OFF until
there is any Report by Exception/Alarms.

B. Through ModBus Poll

Step 1 :

Keep the i-Sens in Configuration Mode.

Step 2 :

Open a new MB Poll window with i-Sens ID= 245.

Poll Holding Registers: 65 (AI channel 1 Alarm Raw Count Min value) Default is 0- no alarm.
Poll Holding Register: 66 (AI channel 1 Alarm Raw Count Max value) Default is 0 - no alarm.
Poll Holding Register: 67 (AI channel 1 Alarm Percentage Change) Default is 0 - no alarm.
Note 1: Data type of these registers must be Unsigned Integer.

Step 3:

Click on the Send button to write it into the i-Sens controller.

Step 4:
Give Inputs on analog channels of i-Sens.When i-Sens wakes up next time, you
can see the changes. You can do the same for all AI channels.
Note 2: Holding Register: 69 -71 (For Channel 2 Alarms)

75

Holding Register: 73 -75 (For Channel 3 Alarms)


Holding Register: 77 -79 (For Channel 4-battery Alarms)

Step 5: Poll Input Status: 86 -100 with iRecv ID=1(Active Alarm Indicator for VRD 1 to 15)
Note 3: i-Sens does not create any Alarm status flags on itself but it creates the analog status flags on
iRecv. The status flag will be 1 when there is a change and it will be retained unless it is being Cleared or
there is an appropriate change in analog values.

Step 6: To clear Alarms, Poll Coil Status:12 with iRecv ID=1. Click ON and it will reset
all alarms to zero upon the next transmitting wake up time. When i-Sens Communicates with
iRecv using Radios, you can still poll the above registers with i-Sens Slave ID.

76

Configure i-Sens Digital Input Channels for Report By Exception(Alarms)

A. Through ICONFIG

Step 1:

In ICONFIG, open the project and Click on the i-Sens. It will show you the
Properties window. Click on Alarms Tab.

Step 2:

Select DI Channel Alarms. Select :


1) Sample Alarm = ON
2) Alarm Value for DI 1= ON
3) Alarm Value for DI 2= ON
You can select any DI channel or both at the same time.

Step 3:

Save and upload the settings to i-Sens. Before upload the settings, keep the i-Sens
in Configuration Mode.

Step 4: To upload the configuration, Right click on i-Sens and select upload
configuration via i-Sens.

77

Step 5: Select the tabs values you want to upload. You can choose what tabs to configure
and upload.
Step 6:
Step 7:

Once selected, all or partial, press OK to upload the configuration.


After uploading configuration, do the settings for RS-232 Communication with
iRecv:
1) Turn the 1st switch of the PSW1 block on i-Sens to Open position and
do the settings for communication with iRecv.
2) Connect the Serial Cable to your PCs COM port and 2nd port of iRecv
(TX2+,RX2-,G).Close pins 1-2&3-4 of JP8&JP9 using jumpers as
shown before.
3) Insert appropriate Radios on iRecv and i-Sens and Power ON both.
(Turn ON i-Sens after iRecv)
Note 1: It is better to Turn ON i-Sens after iRecv for better registration of i-Sens
on iRecv.

Step 8:

Give Inputs on Digital Channels of i-Sens.


Note 2: Source +ve to DI+ve of Channels.
Source ve to DI-ve of Channels.

78

Step 9:

Step 10:

Connect to iRecv in ICONFIG. In iRecv communication window, click on


Network Alarms Tab and there you will find if any Channel Alarm is ON or
not and which i-Sens created it.
To clear the Alarms, Right Click on iRecv and select Set Points. Slide onto
Clear Alarms.
Once you clear the alarm, Channel Alarm will show OFF until there is any
Report by Exception/Alarms.
Note 3: Since Digital Input works like a status, sometimes it does not create any status
flags on iRecv for its value change

.
B. Through ModBus Poll

Step 1 :

Keep the i-Sens in Configuration Mode.

Step 2 : Open a new MB Poll window with i-Sens ID= 245.


Poll Coil Status: 32= ON(Turn on Sample Alarm for Digital Inputs).
Poll Coil Status:19= ON (Send Alarm Data-default is ON)
Poll Coil Status:65= ON(Alarm Value for DI 1)
Poll Coil Status: 66= ON(Alarm Value for DI 2)
Step 3:

Click on the Send button each time to write it into the i-Sens controller.
When i-Sens wakes up next time, you will see the changes.

Step 4:

Give Inputs on digital channels of i-Sens.


Poll Input status:86-100 with iRecv ID=1 (Active Alarm Indicator for VRD 1 to 15)
Note 1: i-Sens does not create any Alarm status flags on itself, but it creates the digital
status flags on iRecv. The status flag will be 1 until there is an appropriate change. The
status flag will be 1 when there is a change and it will be retained unless it is being
cleared or there is an appropriate change in digital values.

79

Step 5:

To clear Alarms, poll Coil Status:12 with iRecv ID=1 and Turn ON the register.
It will reset all alarms to zero upon the next transmitting wake up time.
When i-Sens Communicates with iRecv using Radios, you can still poll the above
registers with i-Sens Slave ID.

80

Jumper Settings for iSens Rev 0.0


Jumper
Number
JP1
JP2
JP3
JP4
JP5
JP6
JP7
JP8
JP9
JP10
PSW1

PSW2

PSW2

PSW2

SW1
SW2
SW3
SW4

Setting

1 (OFF)
2 (ON)
3 (OFF)
4 (OFF)
1
OFF
ON
2
OFF
ON
3
OFF
ON

Description
Main power connector (3.5V to 15V)
I2C connector
Tank Monitor connector
Analog Out connector
Analog In 1 (A1) connector
Analog In 2 (A2) connector
Analog In 3 (A3) connector
Digital Ins connector
Digital Out connector
RS232 Connector
Set to ON to go to configuration
Set to ON to power LED
Set to ON to power the DAC circuit
Set to ON to bypass the reverse protection diode
Read current (0-23.1mA) for A1
Read voltage (0-5.12) for A1
Read current (0-23.1mA) for A2
Read voltage (0-5.12) for A2
Read current (0-22.6mA) for A3
Read voltage (0-5.00) for A3
Power switch or jumper to enable power to board
Switch or jumper to select 10V or 15V for sensors
Download switch
Force Transmit switch and hardware trigger (INT0)

81

Voltage Sensor Mode

iSens can be configured to process analog data in the ranges described in the section
iSens Sensor Connection. Analog signals can be connected either as single ended or
differential. The only real distinction is in how the external wiring is done.
Differential connection tends to be more immune to common mode and ground loop
problems. Regardless, the digital output provided by iSens to the Gateway is 0 - 65535
in decimal linearly, with 65535 representing channel full scale. Inputs are sampled by
the microprocessor in a 20-microsecond window at intervals equal to the supervisory
rate.
When sensors are powered by the internal circuitry, power is applied to the sensor and
held for user selectable times, in 20 millisecond increments from 20 milliseconds to 3
seconds, prior to sampling. This is to allow the sensor electronics to stabilize prior to
sampling. This is also called Sensor Wake-up time, which can be configured through
firmware.
For low power sensors (5-12 VDC @ 3-5 mA), this has a small but finite effect on battery
life, so the shortest "settling time" and lowest applied voltage that is useful should be
used. Note that each sensor channel cannot have different operating voltages applied.
The voltage selected will be common to all channels.
Input voltage = count * 5 / 65535

Current Loop Sensor Mode

This mode is identical to the Voltage Sensor Mode except that the input voltage is
developed by the loop current drop across a high accuracy shunt resistor. When
programmed to the Current Sensor Mode, the required resistor value is 250 Ohms. This
enables an input current range of 0 22.5 mA . This resistor is implemented in iSens
by switching corresponding SW on circuit board as per the table above.
4-20 mA loop powered devices are powered from the iSens by the same method
described above for voltage sensors using the same rule of lowest voltage and shortest
settling time. This is particularly important for current loops, as the power used is
significantly higher and can dramatically affect battery life. See Using iSens to Power 420mA Loop Systems for a further discussion of 4-20 mA iSens powered sensors. The
input current reads up to 22.5 mA.
Input current = (count * 5 / 65535) / 222.1432

82

Configuring the iSens to support 4-20mA sensors


This chapter describes the precautions that must be taken when using the iSens to
power 4-20mA loops.
Not all 4-20 mA loop powered transducers are alike. Some precautions must be taken
before using the ISENS to power 4-20 mA loops. The maximum voltage available from
iSens for loop power is 15 VDC. All 4-20 mA sensors have a stated "operating area,"
which is related to input voltage and loop resistance. The loop resistance is the sum of
line (wire) resistance and the shunt resistance used to measure current. For the
internal iSens shunt, the resistance is 50 Ohms, depending on the jumper settings.
Most manufacturers state operating areas with a simple formula, such as:


Required supply voltage = 10V + (.02 * Loop Resistance)

If, in this particular case, the connecting wires have a resistance of 3 Ohms and the
internal shunt is 50 Ohms, the required voltage is:


10 + (.02 *(50 + 3)), or 11.06 volts

iSens can supply this sensor with 12 Volts of power.


Some of the newer, multifunctional, digital sensors that provide 4-20 mA as a
secondary output path are designed for standard 24 VDC SCADA supplies. These will
generally work in the 4-20 mA mode with lower loop voltage, but tend to have operating
areas bounded at the low end by 12 Volts into 0 Ohms. These will probably work with
12-15 Volts, but test first!
One other caution concerning digital, multivariable sensors is that they usually require
1 to 2 seconds after application of power to stabilize and produce accurate readings.
This long operating period produces a serious current drain and can greatly reduce
battery life. In the extreme case, it can cause voltage sag from the iSens, resulting in
serious accuracy degradation.
All 4-20 mA sensors require some finite "settling" time TO GIVE A GOOD READING;
however, analog devices tend to require far less time than the newer digital equipment,
averaging 20 milliseconds or less. For any 4-20 mA sensor, this "settling time" should
be verified either by information from the manufacturer or by testing before the device
is used. Devices specifically designed for 24 VDC power cannot be powered by an iSens.

83

4.0 Installing a iSens


Pre-installation
Installation must comply with EN60079-14. Install the i-Trasmit in accordance with the wiring
methods, as specified in Article 501-4(b) in the National Electric Code, NFPA 70.

Prior to field installation, the following actions should be


completed:

Determine whether internal battery or external power is to be used.

Based on information from this manual, determine the following transmitter


parameters required for your particular implementation:
a. Type of input (0 20 mA based on switch settings, 0 5 V, status, RTD,
etc.) for each channel
b. Transmitter identification codes, such as transmitter ID
c. Wakeup interval (time for power saving mode)
d. DC power to sensors 10 V or 15 V
e. Sensor settling time

ACCORDINGLY, THE ISENS FIRMWARE NEEDS TO BE


CONFIGURED AND THE JUMPERS/SWITCHES ON THE BOARD
MUST BE SET.

84

Enclosure Mounting Configuration


Prior to mounting, ensure that the SW1 switch on the iSens is securely in the OFF
position.

WARNING: EXPLOSION HAZARD - SUBSTITUTION OF


COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS 1, DIVISION 2.

The iSens is a non-incendiary device enclosed in a NEMA 4X rated class 1 div 2 rating.
To function as a non-incendiary device, the iSens must be connected only to nonincendiary external sensing devices using the conduit entry points into the lower
housing wall. This equipment is NOT field repairable.


Install the iSens enclosure at a conveniently accessible location.

Install the iSens enclosure near the sensor or group of sensors to be sampled. Keep
the sensor cable length optimal to avoid power loss.

Install the iSens enclosure using the housing base mounting ears if to be mounted
on a wall. The iSens in an explosion-proof housing can be mounted on process
piping when integrated with sensors.

Install and contain the wire harness from the sensors to the iSens transmitter via
location approved applicable conduit/outdoor cables. Install in accordance with
wiring methods as specified in Article 501-4(b) in the National Electric Code, NFPA
70.

85

CONNECTING THE ISENS BOARD TO THE POWER SOURCE

Battery Power Operation


Caution! Observe battery polarity while connecting battery pack.

WARNING: EXPLOSION-HAZARD - DO NOT REPLACE BATTERIES


UNLESS POWER HAS BEEN SWITCHED OFF AND THE AREA IS
KNOWN TO BE NON-HAZARDOUS.

Connect the harness of the battery pack to the battery power terminal connector on
the main board ensuring the proper polarity of battery power to the board.

DC Line Power Operation


Caution! Observe DC polarity while connecting external power supply

86

WARNING: EXPLOSION-HAZARD - USE UL/CE APPROVED CLASS 2


POWER SUPPLY AS EXTERNAL POWER SOURCE.

Pull the user's external 6 to 16 volt DC wires through one of the conduit entry points in
the lower housing wall. Connect the appropriate stripped and tinned wire ends of the
external DC line power to DC supply terminals.

Connecting Sensors
Ensure that all wiring enters the iSens enclosure through weatherproof conduit and/or
conduit fittings, as per the appropriate following sections of the National Electric Code.

Area

National Electric Code reference

Cl. 1 Div 1 Area


Cl. 1 Div 2 Area
Cl. 2 Div 1 Area
Cl. 2 Div 2Area
Cl. 3
Intrinsic Safe Systems

Refer to section 501.4.A of NEC Code


Refer to section 501.4.B of NEC Code
Refer to section 502.4.A of NEC Code
Refer to section 502.4.B of NEC Code
Refer to section 503.3 of NEC Code
Refer to section 504 of NEC Code
Refer to section 505.15 of NEC Code
(Applicable only when specified by the end user.)

Cl. 1 Zone 0, 1 & 2

WARNING: EXPLOSION-HAZARD - DO NOT MAKE OR BREAK


CIRCUIT CONNECTIONS WHILE POWER IS ON UNLESS AREA IS
KNOWN TO BE NON-HAZARDOUS.

The iSens sensor interface board is capable of supporting 3 analogs, two digital sensors
and one hardware interrupt device. For each sensor, locate and connect the stripped
and tinned wire ends of the external sensor DC power and return lines to the V and G
screw terminals on the terminal block for each channel.
Locate and connect the stripped and tinned wire ends of the external sensor output
signal and return to the screw terminals A and G.
If the sensor output signal is a current loop, locate the 50/249 Ohm resistor enable
jumper (JP1, JP2, JP3, JP4, JP5 and JP6) on the iSens main board next to the
appropriate sensor I/O terminal block. For 0 22.5 mA, the jumper is selected. There
is a 249 Ohm resistor on-board that gets enabled in the circuit for current loop.

87

Notice: Any grounding or common connection of sensor cable shields


shall be done on the conduit box nipple. No power, safety, or earth
ground connections are to be made to the circuit board, circuit board
mounting bracket or terminals.

iSens Board

Each I/O Point signal input will be independently configurable into one of two modes as listed
below:
I/O Point Mode

Sensor I/O Description

A
B

Single Ended Voltage Sensor (0 5 VDC)


Single Ended Current Sensor (0 22.5 mA)

88

Mode A - I/O Point Single Ended Voltage Sensor


In Single Ended Voltage Sensor Mode, the I/O Point may optionally provide power to the sensor and will
be programmable during setup to accept a voltage in the 0 5V DC input range.
For full accuracy, the loop resistance to the sensor should be less than 100 Ohms. In this mode, the I/O
Point, depending on power source, will be wired as shown in the following figures:
iSens Mode A with iSens Module Supplied Power

iSens Mode A with External Power

Mode B - I/O Point Single Ended Current Loop


In Single Ended Current Loop Sensor Mode, the I/O Point may optionally provide power to the sensor
and will detect currents in the range from 0 to 22.5 mA. For full accuracy, the loop leakage current
should be less than 5A.
The internal precision 249 Ohm resistor must be selected with the corrosion resistant hardware jumper
supplied and located just below the channel input terminal block. Wiring is as shown in the following
figures.

89

iSens Mode B with iSens Module Supplied Power

When powering more than two 4-20 mA current loop sensors, a special
high current battery pack should be used in place of, or with, the standard
battery pack.

iSens Mode B with External Power

90

Monitoring a Project
The i-Config user Interface provides the user access to basic data monitoring and network diagnostics.
Once an iSens is created and all devices are configured, the system can be tested by connecting the iRecv to a PC running i-Config.
If you select a specific i-Recv in the Network, and double click the icon in the Project Explorer Pane, a
tabular report will appear in the middle of the application screen displaying the i-Recv name and
showing basic data for all associated iSens.

This screen will show basic diagnostics data for each associated iSens.
This report will also have several tabs with each tab providing a significant amount of data about the
network operating state and diagnostics data for proper troubleshooting of the system.

91

4.1 i-Recv Diagnostics Report


4.1.1 Network Info Tab

The Network Info Tab provides data about all associated iSens including registration status,
Operating Mode, and iSens status.
4.12 Triggered Calculations Tab

The Triggered calculations tab provides data about the calculations or any mathematical
operation the iSens are executing. This would include calculating Engineering units, Square
Roots or linear accumulation or alarms.
4.1.3 Network Alarms Tab

The Network Alarms tab provides data about the alarms triggered by any of the associated
iSens. Any alarm that is triggered on a specific iSens based on Min, Max or percent change will
be reflected in this screen.
4.1.4 WMP Msg Status

The Wireless Message Protocol WMP Msg Status tab provides data about the communications
status between all associated iSens and the i-Recv. This includes data such as Time Since Last
Message, time stamp of last message, time till next message (calculated based on iSens
configuration) and a number of messages received from each iSens.
4.1.5 Network RF Status

The Network RF Status tab provides data about the RF signal status between the iSens and the iRecv and provides data about bad messages received from each associated iSens.
4.1.6 Debug

The Debug tab provides a powerful tool to log data and message format to allow an advanced
user to decode messages and detect the source of errors if they are occurring.

92

iSens Diagnostics Report i-Report and i-Chart


For monitoring any associated iSens, double click the particular iSens, and another tabular report will
appear showing all data and I/O channels from that particular iSens.

The report will have two separate tabs, i-Report and i-Chart
4.2.1 i-Report

i-Report provides the user a snapshot of the selected iSens will all I/O analog and digital current
reading. The i-Report will display all Analog values in both Raw digital count or engineering value
if the engineering value calculation is triggered.

93

4.2.2 i-Chart
i-Chart will provide the user a time based trend starting at time 0. This refers to the time a user
selects an iSens report and presses the green Start Button. The i-Chart can be configured for
Zooming in or out, saved and printed. All values, colors, and scales can be changed and adjusted
to fit the user preferences.

94

Maintenance
This chapter provides instructions for maintaining iSens transmitters. This chapter also
contains a troubleshooting guide for diagnosing possible problems with the transmitter
unit.

Warning: Explosion Hazard - Always turn the ON-OFF switch to the OFF
position and disconnect the power source prior to any maintenance work.
Keep lid tight and do not open when an explosive gas may be present.

iSens transmitters are designed for minimal maintenance and no field repairs.
Changing the batteries is the only scheduled maintenance activity. The batteries for the
ISENS transmitter are rated for 1 to 5 years of life based on the sampling time, number
of sensors, and whether or not the sensors are loop powered. Typically, if the sensors
are externally powered, you can use the batteries for maximum life. In such case, a
Class II power supply is required for instrument loop power.

Warning: Explosion Hazard - When in hazardous locations,


decommission the unit and service it in a gas-free environment outside
classified area.

The latest version of i-Sens transmitters internally sense the battery power and send
this data to the receiver as part of the data packet using the serial interface to the
receiver. A remote operator receives a 20-30 day notice to schedule maintenance activity
before the batteries are completely drained.
The only maintenance tools that a technician needs for maintenance of
iSens transmitters are a medium sized screwdriver, terminal sized screwdriver and a
multimeter.

Warning: Always clean the equipment with a dampened cloth rather than
a dry piece of cloth.

95

Troubleshooting Guide
The following is a comprehensive troubleshooting guide written for easy maintenance of
the transmitter unit:
1. RED LED is not ON.


Cause: Power issues. Most likely the transmitter is not getting enough power to boot
up.

Action: Open up the iSens transmitter enclosure and check the power supply.
Check if the voltage across the battery leads or the power connector is greater than
6.0 V.

If the iSens is battery powered, check if the battery is dead or on low-voltage. If the
iSens is externally powered, check the power supply wiring.
If the problem persists, decommission the unit and send back to vMonitor for repairs.
2. The Transmitter is not powering the sensor. There are no readings displayed on the
Sensor LCD screen.


Cause:
Most likely the transmitter does not have enough power to power the
sensors or the unit has insufficient sensor settling/wakeup time.

Action:
iSens is designed for power-save mode. During this mode, there is no
power to sensors. When the iSens comes out of sleep mode for Acquisition/Transmit
mode, you can measure voltage at V and G terminals. This is when the iSens loop
powers the sensors, gets the reading, and transmits over radio link.

If you see power on V and G terminals, verify the sensor settling time with the
Manufacturer. Crosscheck the settling time in iSens firmware.
3. The operation of the unit looks fine with alternate power save mode and transmit
modes, but there is no data at the Gateway.


Cause 1:

Radio module is not placed securely and firmly.

Action 1:

Verify the installation of the radio module.

Cause 2:

Incorrect Jumper settings.

Action 2:

Verify the settings for JP1, JP2, JP3, JP4, JP5 and JP6.

Cause 3: Radio communication issues, such as antenna misalignment, external


interference, bad signal, high noise in signal, faded signal, bad antenna cable, bad
antenna connectors, loose jumper cable connections, lightning strike, bad
transmitter, incorrect polling of TX ID or Modbus registers.

Action 3: Consider all of the above cases and rule out the possibilities one-by-one.
Repeat the same checks for the master station.

96

New Firmware, i-Recv


The i-Recv will have the latest firmware version loaded, however if a new firmware is required,
the following procedure will allow a user to download a new firmware into the i-Recv.
The following tools are needed to upload the new firmware.
Computer with a serial port
HyperTerminal with i-Config application

Setup Hyper Terminal for 9600, 8 N &1 for the corresponding serial port.

Power off the i-Recv.

Press and hold Switch 4 (SW4).

While holding SW4 power the i-Recv, a smile face must show in Hyper-terminal.

The i-Recv program is interrupted now and is ready to receive the new code.

Disconnect or close Hyperterminal.

Open i-Config application.

Click on Upload Hex File on the icon bar as shown below

A window will pop up to choose the Hex file to download.

Once selected, choose open, the firmware download will initiate.

Once completed the process is ready and the i-Recv now has a new firmware. It is also
back to default configuration.

97

Checklist
Mount iSens Remote Device with antenna straight up
Attach conduit and sensors as required & feed wire through to wiring compartment
Complete sensor wiring
Set dip switches, selecting between voltage or current input
Make power connection
Close the iSens Remote Device
Mount i-Recv
Mount Antenna, straight up, attach antenna to i-Recv
Load the i-Config User Interface software into PC
Attach PC to i-Recv
Attach and apply power to i-Recv
Start i-Config User Interface software
Observe the set up page
Name each iSens Remote Device and indicate any iSens which would be supported by another i-Recv
and ignored by this i-Recv
Indicate the order in which the iSens are to be displayed
Set the sampling interval for each iSens
Set the transmission interval for each iSens
Label each sensor on each iSens Remote Device
Indicate the unit label for each sensor: mA or V
Indicate whether each sensor is an interrupting sensor, or purely a sampling sensor
For each analog interrupting sensor, determine the change which would trigger an interrupt
For each digital sensor determine whether the indication is normally on or normally off

98

Map the data from each sensor to a Modbus register


Map the data from selected Modbus registers to the discrete outputs
Attach discrete outputs to a local Flow Computer, RTU or PLC
Attach Modbus cable to local Flow Computer, RTU or PLC
Switch to the data monitoring page and observe the collected data

Backup Mode: Configures the device to operate as a backup. A gateway that is configured to be a
backup receives all messages from the transmitters, but does not respond to them. A backup i-Recv
shares a Slave ID with the active i-Recv and can be switched from backup mode to active in the event
that the active i-Recv fails.

99

Mapping Register
i-Sens Coil
Address
1-4
5-8
9
10
11
12
13
14
15-16
17
18
19
20
21-24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44-64
65
66
67-100

Description
Digital Output
Reserved
Reset Board
Restore Defaults
Restore Factory Defaults
Clear Alarms
Reserved
Reset Received/Sent Message Counts
Reserved
Send Basic Data (Raw Count, EU, Digital Status, Response Time and Message
Count) Message Flag (default is on)
Reserved
Send Alarm Data (default is on)
Send Config Data after sending Register Msg
Reserved
Shut down modem in sleep mode
Provide Power to Sensor when waking up
Encryption is On (cannot be changed)
Battery Diode Flag (default is on)
Reserved
Reserved
Use Time Synchronzation for Reporting
Turn on Sample Alarm for Digital Inputs
Register Message Ack Flag (only for i-Sens)
Un-Register Message Ack Flag (only for i-Sens)
Basic Message Ack Flag (only for i-Sens)
Reserved
Reserved
Send Next Mail Box Message Ack Flag
Reserved
Reboot Message Ack Flag (only for i-Sens)
Modbus Read Request Message Ack Flag (only for i-Sens)
Modbus Write Request Message Ack Flag (only for i-Sens)
Modbus Response Message Ack Flag (iRecv Only)
Reserved
Alarm Value for DI 1
Alarm Value for DI 2
Reserved

Default

TRUE
FALSE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE

FALSE
TRUE
TRUE
TRUE
TRUE

TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE

100

i-Sens Status
Address
1-4
5-8
9-12
13-16
17-20
21-24
25-32
33-40

Description
Digital Input
Reserved
Min/Max Alarms for AI channels (1-4) status flags
Reserved
Percent Change Alarm for AI channels (1-4) status flags
Reserved
Reserved
Reserved

i-Sens Input
Address
1
2-3
4-5
6
7
8
9
10
11-20
21-22
23
24
25-26
27-28
29
30
31-39
40-43
44-51
52-59
60-61
62-65
66-75

Description
i-Sens MODBUS Slave ID
Serial number
Firmware version number (float)
Hardware Type
Actual Slave ID (when we are in Configuration Mode Register 1 is changed to
ID 100)
Actual Operating Mode (when we are in Configuration mode this register
reflects the actual mode)
Reserved
Number of registration attempts
Reserved
Board Current Time
Time since last received message
Message Response Time (time to receive ACK message)
Number of Messages Sent since start
Number of messages Received since start
Reserved (internal Wake up counter)
Reserved (Signal Strength Wake up counter)
Reserved
Raw Counts for Analog channel 1-4
Reserved (internal voltage values)
Eng Units for AI channels 1-4
internal Board Temperature
Last Raw Count value for channel 1-4
Reserved (internal Msg header)

101

75-78
79-80
81-180
181
181
182:183

Reserved (last 3 msg IDs)


Reserved (Password Timer)
History data for analog input channels 1-4 (81 msg ID # 1 with 82-85 registers
are raw data for msg ID # 1, 86 msg ID # 2, 87-90 raw data for msg ID # 2,
etc)
last adjusted sleep time
Signal Quality Strength (ZIBGEE Pro Radio is 36-100)
Last Time Signal Strength was measured

i-Sens Holding
Address
1
2
3
4
5
6
7
8
9
10
11
12
13

14
15
16
17
18
19
20
21
22
23

24
25
26
27
28
29
30

Description

Default

Prmary i-Recv Slave ID To report to


Secondary i-Recv Slave ID to report to
Sleep Internal (in seconds)
Sample Rate in milliseconds (Power Mode Only)
Pulse Reset Time (in seconds from Midnight) (Power Mode Only)
Sensor Settling Time (in milliseconds)
Modem Settling Time (in milliseconds)
Delay before Shutting the Modem down after sending data (in milliseconds)
Delay between message transmissions (in milliseconds)
Delay before Sleeping (in milliseconds)
Time Zone
Analog Out Settling Time (setting this will cause the AO to written for this amount of time
then reset to 0)
Hour Time Offset to sync reporting (-1 is disabled, 1 means that the report interval is
adjusted to be offseted by 1 min so if the report interval is 5 min then we will transmit data
at 6 min, 11 min, 16 min ,etc)

1
0
30
10
0
50
50
10
10
10
0
1000

Digital Output Setting Time (setting this will cause the DO to be written for this amount of
time then reset to 0 after time expires)
Operation Mode (1-battery, 2-power, 3-modbus)
COM Baud Rate
COM Parity
COM Stop bits
COM Data bits
Differential Channel Type
Msg Ack time out (in seconds, default is 2)
Msg Ack Retry Count (default is 1)
Report Transmit Factor (this is used with register 3 sleep time to determine how often to
report to the iRecv. So if this value is set to 10 and register 3 is set to 60 seconds then iSens will report every 10 min to the iRecv unless there is an alarm)
Radio API Mode (0-off, 100-On)
Raw Min Count for AI Channel # 1
Raw Max Count for AI Channel # 1
Reserved
Reserved
Reserved
Reserved

500

1
9600
0
1
8
0
2
1
10

100
12840
65535
0
0
0
0

102

31-32
33-34
35-44
45-54
55-64
65
66
67
68
69-72
73-76
77-80
81-82
83-84
85-88
89-92
93-96
97-100
101-104
105-108
109-110
111-112
113-114
115-116
117-118
119-122
123
124-125
126
127
128
129
130-140
141-142
143-144
145
146-147
148-149
150-151
152-153
154-155
156-157
158-159
160-161

Engineering Low for AI Channel # 1


Engineering Max for AI Channel # 1
same as registers 25-34 for AI channel # 2
same as registers 25-34 for AI channel # 3
same as registers 25-34 for AI channel # 4
AI channel # 1 Alarm raw count Min value (default is 0 - no alarm)
AI channel # 1 Alarm raw count Max value (default is 0 - no alarm)
AI channel # 1 Alarm Percent Change (1 represent 1% change, 15 is 15% change, etc)
(default is 0 - no alarm)
Reserved
same as registers 72-74 for AI channel # 2
same as registers 72-74 for AI channel # 3
same as registers 72-74 for AI channel # 4
Smoothing Factor for AI channel # 1
Resis Value for AI channel # 1
same as registers 87-90 for AI channel # 2
same as registers 87-90 for AI channel # 3
same as registers 87-90 for AI channel # 4
Analog Input Channels 1-4 Type (0-inactive, 1-current, 2-voltage, 3-battery, 4-Temp, 5humidity, 5-rssi)
Digital Input channels 1-4 Type (3-inactive, 0-digital, 1-Pulse Counter, 2-Pulse
Accumulation)
Analog Output Channels 1-4 Type (0-inactive, 1-current, 2-voltage)
Analog Output Coeff factor
Analog Output Constant
Analog Output Correction Factor
Analog Output Correction 1st Poly Coeff (2nd Poly Eq)
Analog Output Correction 2nd Poly Coeff (2nd Poly Eq)
Analog Output for AO channels 1-4
Set new Slave ID
Set Board Time (unix time since 1970)
Reserved
Max time to download Mail Box messages
Reset Comm Port Idle Time (in seconds - default is 10)
Max Registration Attempts
Reserved
Password Value
New Hardware Serial Number
Calibration Type (0-Raw Count, 1-Current, 2-Volt)
Low Calib for Channel 1
High Calib for Channel 1
Low Calib for Channel 2
High Calib for Channel 2
Low Calib for Channel 3
High Calib for Channel 3
Low Calib for Channel 4
High Calib for Channel 4

0.0
1500
~
~

0
1
~
~
~
1,1,1,3
0,0,3,3
1,1,0,0
204.918
-0.002
1.0
0.0

0
0
10
10
10
~

0
12840
64000
12840
64000
13280
65535
13280
65535

103