Heath Consultants Heath Data Recorder User Manual

Heath Consultants Incorporated Houston, TX 713-844-1300 Fax: 713-844-1309

1-800-HEATH-US

www.heathus.com

Heath Data Recorder

HDR Series

User’s Manual & Field Installation Guide

HDR Series

HDR User’s Manual & Field Installation Guide

Proprietary Notice

The contents of this manual are proprietary to Heath Consultants Incorporated. Reproduction of this manual, in whole or in part, is prohibited without the express written consent of Heath Consultants Incorporated.

Heath Consultants Incorporated operates under a continual product improvement program and reserves the right to make improvements and/or changes without prior notification.

Purpose of this Manual

The HDR is a powerful device that can be assembled and programmed in a variety of configurations. The purpose of this manual is to provide information for use in instrument shop setup and field installations.

Models

HDR Portable I.S. HPN 77R91-1001-1 HDR Wall Mount I.S. HPN 77R91-1002-2 HDR Pipe Mount I.S. HPN 77R91-1003-3 HDR Portable HPN 77R91-1001 HDR Wall Mount HPN 77R91-1002 HDR Pipe Mount HPN 77R91-1003

Table of Contents

HDR I.S. Series (Purpose of this manual) ....................................................................................... 2

Table of Contents ............................................................................................................................ 3

Heath Data Recorder (HDR) Overview .......................................................................................... 4

HDR Features .................................................................................................................................. 5

HDR PCB Layout ............................................................................................................................ 6

Mounting & Installation .................................................................................................................. 7

Housing Configuration .................................................................................................................... 7

Pressure(s) Connection .................................................................................................................... 7

Temperature Probe(s) Installation ................................................................................................... 7

Electrical Installation ....................................................................................................................... 7

Battery Pack & Back-up Batteries ................................................................................................... 8

External Power ................................................................................................................................ 8

External Modem .............................................................................................................................. 9

Internal Modem ............................................................................................................................. 10

Call-out upon Alarm wiring (when connected to Heath 2400 baud modem) ............................... 10

HDR Host Operating Software...................................................................................................... 11

Software Installation ............................................................................................................ 11-15

Quick Start Guide ..................................................................................................................... 15

HDR Configuration Detailed .................................................................................................... 16

User Friendly Names ................................................................................................................ 16

Site info and Instrument Modem .............................................................................................. 16

Pulse outputs ............................................................................................................................. 17

Alarm Configuration ................................................................................................................. 18

Alarms Reset using scroll button .............................................................................................. 18

Setting up “Call Out upon alarm” ............................................................................................. 18

Configure LCD sequence .......................................................................................................... 19

Configure Profiler ..................................................................................................................... 19

Watch Log ................................................................................................................................. 20

Fast Log(s) ................................................................................................................................ 20

Set Real Time Clock ................................................................................................................. 20

Set Access Control (Security access passwords) ...................................................................... 21

Reset Instrument (Alarms/ logs etc.) ........................................................................................ 21

Auto Configure (saving/ restoring instrument CFG) ................................................................ 22

Adding a Transducer ..................................................................................................................... 22

Modbus Implementation................................................................................................................ 23

Downloading and Printing Data .................................................................................................... 23

Configuring for use with an IP Modem.................................................................................... 24-30

HDR Profiler Memory Capacity Table ......................................................................................... 31

HDR Firmware Update Procedure ........................................................................................... 32-35

Specifications ................................................................................................................................ 36

HDR Maintenance and Troubleshooting ....................................................................................... 37

Periodic Maintenance/ Annual Checks ......................................................................................... 38

Maintenance Procedures (Calibration, Main Battery change & Backup/Restore Inst) ............ 39

Back-up Battery Replacement Procedure ................................................................................. 40-41

Spare Parts and Accessories .......................................................................................................... 42

Service Information: Warranties and Warranty Repair ................................................................. 43

Configuration Worksheet .............................................................................................................. 44

Technical Support.......................................................................................................................... 45

External Power Connector

Heath Data Recorder (HDR) Overview

LCD Display

Scroll Button (on bottom)

External Modem cable Port

Temperature probe Ports 1 & 2

Pressure Ports 1, 2, 3

RS232 PC Comm.

Back-up Battery (under cover)

Primary Battery

Modem Battery (If equipped)

Internal 2400 baud Modem (If equipped)

Earth Ground Stud (on bottom)

Primary Battery Connector

The HDR is a microprocessor based, self-contained system designed for the purpose of process monitoring using integral pressures and temperatures. Figures 1 illustrates the location of major components and user interface items.

Figure 1: General configuration of the HDR

HDR Features

• Handles up to three pressures (3) and two (2) temperatures (plus ambient).

• Intrinsically safe: Class I Div I Group D (without internal modem).

• Measures, records & alarms on all connected sensors every second.

• Single Alkaline “D” battery provides power for up to 4 years.

• Single Lithium “AA” Backup battery will provide 100% operation for up to 1 year after main battery is depleted.

• Wall mount, Pipe mount and Portable configuration options.

• Continuous LCD displays all inputs (selectable with scroll button): up to three pressures, two temps, ambient temp,

Main battery voltage, B/U Lithium battery voltage and active alarms. These readings are updated every second.

• 16 fully customizable alarms with logging of time and readings at the time of trip & reset on all selected alarms.

• Active alarms can be configured to blink the LCD reading every second. Scroll LCD to read the active alarm.

• Alarms can be configured to reset automatically or manually.

• Alarm Log (Records Alarm timestamps- Set & Reset).

• Delta alarms can identify and record spikes in the readings every second.

• Alarm call out to pager or phone (up to 3 phone numbers) upon any or all alarms.

• Profiler data recording (up to 20 items)/ Circular log: Selectable intervals: (1 min/ 5 min/ 10 min/ 15 min/ 30 min/ 60

min). Time/ Ave/Min/Max- Pressures 1 & 2 & 3 (If equipped)/ Ave/Min/Max- Gas Temperature 1 & 2 (if equipped) & Ave/Min/Max ambient temp/ Main battery voltage & pulse inputs.

• Profiler selectable memory size (50,400 up to 403,200).

• “Fast logs”- (3) independent, high resolution event capture logs records and captures pressure data every second

(High, Low or Delta, selectable) for one hour total (30 minutes before the trip point and 30 minutes after).

• “Watch log”- provides an additional high resolution circular pressure data log. Recording options are: logging data

every second for 9 hours of memory storage or averaging 2 second data for 18 hours or 4 second ave. for 36 hours or 8 second ave. for 72 hours (3 days) or 16 second ave. for 144 hours (6 days) and generates an Excel file automatically when viewed.

• Config Log (Records configuration changes made to the instrument).

• Remote Communications Ready (External Direct port & Internal Remote RS232’s).

• Multi-Drop ready- Connect remotely to several instruments from one modem (Up to 62).

• Protocols included: Sandia (Native)/ Modbus ASCII (RTU available in a future release).

• PDC (Portable Data Collector) can download & store up to 166 full profilers. No PC needed to get field data.

• Units of measure (PSIG, Ozsi G, H2O G, kPa G or Bar G, Deg. F/ Deg. C).

• Pressure ranges (shown as PSIG): 1, 3, 6, 15, 30, 60, 100, 150, 300, 500, 1000, 2000, 3000, 5000

• HDR firmware can be upgraded via PC.

• Non-volatile Flash memory saves Calibration, Transducer Coefficients, Configuration & Site info if all power is lost.

• Housing is IP64, Aluminum, Powder coated paint over chromate surface prep, lockable stainless steel hasp closure.

• HDR Host is compatible with Windows 8, Windows 7, Win Vista and Win XP.

• HDR Host is very user friendly software for configuration, calibration and data processing.

• Single PC Board design simplifies cabling and setup.

• Compact packaging for easy transport and installation.

CTS

RTSCDTXM

RXM

GND

PULSE INPUT

GND

TXD

RXD

PULSE OUT B

GND

PULSE OUT A

GND

P3 +E

P3 +S

P3 -E

P3 -S

GND

P2 +E

P2 +S

P2 -E

P2 -S

GND

P1 +E

P1 +S

P1 -E

P1 -S

GND

GAS TEMP

GND

INDEX B

STOBE

INDEX A

STOBE

3V SYS

GND

GAS TEMP 2

1.5VDC GND

12VDC

GND

BUTTON

COM 2

COM 1

PRESS 3 PRESS 2 PRESS 1

JP5*

CR2032

1 2 3

ASSY#: 77R65-9320

REV F

3.6V "AA" Lithium

OPEN

JP1*

INDEX INPUT

MAIN BATT CONN

12VDC EXT CONN

DISPLAY

BACKUP BATTERY

BACKUP

BATTERY

MEMORY

(HVC ONLY)

GAS TEMP

PROBE #2

PROBE #1

DATA

MODEM DIRECT

WIRED TO

J13 J14 J11 J10 J7 J6 J5 J9

J12

J11

HDR PCB LAYOUT

NOTE: External connections to the pcboard should be made by acquiring locking harnesses for Modem

connections (J13) and External 12V power (J11), Pulse input (J14) & (2) Pulse outputs (J10). Contact Heath Consultants customer service to get these harnesses.

* JP1: This jumper switches the lithium power from the pcboard circuit. * JP5: When using the internal 2400 baud modem, a special harness is required for “Call out upon alarm”

feature. This harness connects Pin 2 of JP5 to Pin 6 of J13 (External modems that stay online 100% doesn’t require this option).

Mounting & Installation

Housing Configuration

The HDR is available in many

• Pressure: up to three

• Temperature probes: two (plus internal case temp)

configurations.

The maximum number of integral sensors is as follows:

The housing type will determine whether sensor connections are made from the bottom or rear of the instrument as follows:

• Wall/Panel mount: bottom connect

• 2” pipe mount: bottom connect

• Portable: rear connect

Pressure Connection(s)

Connect up to 3 pressure inputs to the 1/4” NPT female connectors located on the bottom or back of the HDR housing. After piping is complete, check all connections to ensure that no leaks are present.

Temperature Probe(s) Installation

If equipped, up to 2 standard 6 foot long temperature probes (6” x 1/4” OD) may be used, and should be installed into the appropriately sized thermowell filled with a thermo conductive medium such as glycol or alcohol. Insert the temperature probes into the thermowells through the standard 1/4” inch NPT male gland (provided) until the tip of the probe reaches the bottom of the well. Secure excess armor cable length of the probe.

It will be necessary to isolate the pressure and temperature connections to the pipeline, so as not to disturb the cathodic protection system.

Electrical Installation

NOTE: Refer to drawing MTM-308-1 for field wiring requirements for external power and modem connections to maintain intrinsic safety.

The HDR unit must be earth grounded to maintain safe operation and warranty.

The ground stud of the HDR (located on the bottom of the instrument) must be connected to a suitable known external earth ground (usually a dedicated ground rod and NOT AC ground). All of the major components in the HDR are bonded together and connected internally to this groundnut. It is required that grounding be performed, especially when an external modem and/or external power supply (which requires a dedicated ground rod in close proximity to the safe area) is used. All cabling connecting to the HDR must be shielded with all shields tied to case ground.

For multiple device interconnections (modems, power supplies etc.) the groundnut of the HDR must be tied directly to this same (safe area) ground rod rather than having a separate ground rod of its own.

The American Gas Association recommends grounding all electronic field devices to a driven ground rod. This will help protect the device from transients including lightning and power surges on the pipeline.

To reduce the possibility of “secondary” lightning strike damage (damage caused by static electricity fields in the immediate area), the above precautions are required. However, these precautions cannot prevent damage to an instrument that receives a “direct” lightning strike.

Battery Pack and Back-up Batteries

The HDR units utilize (1) 1.5-volt, encapsulated “D” cell alkaline battery as its primary power source. The pack supplied with the HDR consists of an alkaline dry cell and a protection circuit. (Part number(s) on page 42) NOTE: This battery is not rechargeable.

HDR units are shipped from the factory powered and ready to install in the field (unless otherwise specified).

The HDR incorporates an on board uninterruptible power supply. This consists of one factory installed “AA” lithium cell (BT1) rated at 3.6 volts. This cell is easily replaced in the field.

The HDR incorporates an on board battery (CR2032) for backup of the profiler log. This consists of a replaceable button style lithium battery (BT2) located on the component side of the PCB.

Normal battery voltage should be displayed between the ranges of 1.2 to 1.5 volts for a new battery, and when the primary power drops below .8 volts, the unit will switch to lithium backup. Under normal conditions, the main battery pack should last up to four years and the lithium backup battery should last up to 1 year without power from the main battery.

Caution: When the communication cable is connected to the instrument, higher than normal battery current is consumed.

Because of this, it’s recommended to limit the time connected to the instrument.

Caution: The maximum voltage allowed on the “Main battery” input is 2 volts DC. Only use the 1.5 volt battery pack

supplied by Heath. If this voltage is exceeded, a protection fuse will blow and the warranty will be voided.

Note: If all three batteries lose power, the data that is stored in non-volatile memory will not be lost. This includes Calibration, Poly (transducer) and configuration data.

Caution: To maintain the Intrinsic Safe rating, use only proper replacement batteries: main battery pack HPN 77R91-

1037, Lithium backup battery, HPN 77R65-8001, and coin battery, HPN 77R65-8002.

Contact Heath Consultants Incorporated for replacement batteries and main battery packs. Refer to Periodic

Maintenance on pages 38-42 for replacement procedures & part numbers.

External Power

The HDR can be connected to an external power source (6- 15VDC). This connection is required when an external modem is used due to the RS232 load on the instrument. A wiring harness is required to connect the external power to the 12 volt source. Note: Contact Heath Consultants Incorporated to get this harness.

CTS

RTSCDTXM

RXM

GND

INDEX B

STOBE

INDEX A

STOBE

3V SYS

GND

GAS TEMP 2

1.5VDC GND

12VDC

GND

BUTTON

JP5

CR2032

1 2 3

ASSY#: 77R65-9320

REV F

3.6V "AA" Lithium

OPEN

JP1

DISPLAY

BACKUP BATTERY

WIRED TO

Modem Wakeup Jumper Wire

CTS

GND

(Only required for modems that power down)

J13

Non-Heath Modem

DSR (Pin 6)

GND (Pin 5)

RX (Pin 2)

TX (Pin 3)

RS-232

Splice

9 Pin

12V GND

12VDC Modem Battery

12V

GND

External Modem

The HDR is equipped with two RS232 communication ports. The Direct Port is dedicated to local direct PC communication at 19200 baud using the HDR com cable. The Remote Port is used for connecting a modem. Remote baud rates available are 300, 1200, 2400 (default), 4800, 9600 and 19200. When configuring for a remote modem, the “Remote Modem Baud Rate” in the unit must match the baud rate of the field modem being used. Connect the RX, TX & GND from the modem to the instrument on J13. A wiring harness is required for this connection.

Note: For proper remote communication using the native protocol Sandia, the modem [default] mode needs to remain.

Modbus mode must be set to “RTU” & “Parity” must be set to “None”.

Note: If the external modem powers down to save power, the CTS wire is required to wake the modem prior to “dialing out upon

alarm”- if this feature is enabled. Otherwise the CTS wire isn’t required for inbound communication.

Caution: When connecting the HDR to an external modem, it is recommended to connect external power to the

instrument due to higher current demand.

External power is recommended When connected to external modems.

CTS

RTSCDTXM

RXM

GND

INDEX B

STOBE

INDEX A

STOBE

3V SYS

GND

GAS TEMP 2

1.5VDC GND

12VDC

GND

BUTTON

JP5

CR2032

1 2 3

ASSY#: 77R65-9320

REV F

3.6V "AA" Lithium

OPEN

JP1*

DISPLAY

BACKUP BATTERY

WIRED TO

*Jumper wire

Yellow (CTS)

Red (GND)

Gray (RXM)

Blue (TXM)

Heath 2400 Baud Modem

(Wake-up wire for "Call Out Upon Alarm")

12V Modem Battery

(Wake-up wire for "Call Out Upon Alarm")

J13

Phone Line

Surge Protector (Optional)

Internal Modem

The HDR may be equipped with an internal modem and phone line surge suppressor. The modem is pre-configured and pre-wired from the factory, ready for remote communication. If the HDR is equipped with the phone line suppressor, it will be connected directly into the modem’s RJ-11 connector. A 12-volt battery pack (8 “AA” batteries) is supplied, but not connected when shipped. The user must connect prior to remote communication. Assuming one two-minute call per day, every day, the battery should provide approximately 2 years of service.

To connect a phone line to the modem, insert the phone cable through the wire gland into the case (see Figure 1). The cable must be terminated with a RJ-11 connector. Plug into surge protector if provided; else plug directly to the modem.

The optional phone line surge suppressor will sacrifice itself to protect the equipment in the event of a destructive power surge on the phone line.

Caution: Unit must be connected to proper ground to allow the surge suppressor to operate properly. Caution: Internal modem option is not currently certified for use in hazardous environments. An external modem should

be used when necessary. Refer to drawing MTM-308-1 for field wiring requirements on external power and modem connections to maintain intrinsic safety.

Internal Modem Wiring (with “Call out upon Alarm”)

Connect the RX, TX, GND & CTS wires from the HDR to the modem using the modem harness required (contact Heath Consultants Inc for this harness). Plug in the jumper wire to JP5.

Note 1: For “Call out upon alarm” feature. The modem harness connects Pin 2 of JP5 to Pin 6 of J13 (Modems

that stay online 100% doesn’t require this jumper).

Note 2: If the “Analog Modem” is NOT selected, the calls will be dialed 2 minutes apart. However, if the “Analog

Modem” is checked, the calls will be completed ASAP (Approximately 20 seconds).

Note 3: A “Manual” alarm must be reset in order to get a second “Call out” alert. An “Auto” alarm will call out

multiple times if the trip points are exceeded in succession.

HDR Host Operating Software

HDR Host is the companion software interface to the HDR instrument. The application program provides for configuration, calibration, local and remote communication, interrogation, data collection and data processing. The program is supplied on CD ROM media. The self expanding executable “setup” file will guide the user through the installation process.

This install will work in Windows operating systems for Win XP, Win Vista, Win 7 & Win 8.

NOTE: HDR Host must be on each workstation, in a network, that utilizes it. The data can be sent to a network drive and be shared by other workstations that have HDR Host installed. Remember to change the “Data Paths” of each workstation to use the same network drive and directory. DO NOT INSTALL THIS SOFTWARE DIRECTLY ONTO THE NETWORK SERVER DRIVE.

Software Installation

To install, locate the file “HDR Host Setup4.02.EXE”. Double-click the file to install. Follow the instructions to complete the installation process. After the software is installed, you may need to configure the com port to directly connect to the instrument. Com 1 is very common; however, many newer computers are not equipped with a 9-pin

connector for direct connect with the standard com cable. A “USB to Serial adapter” may be required. Follow the

instructions included with the USB to serial adapter. After the adapter is installed and connected to the PC, go to “Start”/ Control Panel/ System/ Hardware/ Device Manager/ “Ports” (click the “+” to the left of “ports”) Look for “ATEN USB to Serial Bridge (com xx)” Enter this port number in the HDR Host (Host Setup/ Configure Host)/ “Direct”. Any port from 1-255 can be chosen. Note: Only the available ports will be listed in HDR Host/ Host setup “Name” dropdown.

NOTE: HDR Host requires a screen setting of at least 800 X 600. The bottom of the window may sometimes be out of view.

Click “Next” to continue.

Accept the agreement. Then click “Next” to continue.

Click “Next” to continue or change the default location of the HDR Host data files.

Click “Next” to continue or change the default location of the data log files.

Click “Next” to continue or change the default location of the HDR Host shortcut.

Select additional icons. Click “Next” to continue.

Click “Next” to continue installation.

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