Rockwell Automation 1425 User Manual
User Manual
PowerMonitor Wireless 250 Monitor
Catalog Numbers 1425
Important User Information
IMPORTANT
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1
your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
available from
) describes some
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Rockwell Software, Rockwell Automation, PowerMonitor, RSPower, RSEnergyMetrix, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
PowerMonitor W250 Unit Overview
Hardware Installation
Table of Contents
Preface
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
About the PowerMonitor W250 Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PowerMonitor W250 Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wireless Mesh Network Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wireless Network Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 2
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Network Deployment Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PowerMonitor W250 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PowerMonitor W250 Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Network Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Software Interface
Certifications
Specifications
Glossary
Chapter 3
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
PowerMonitor W250 Modbus Register Table . . . . . . . . . . . . . . . . . . . . . . 35
PC Receiver Modbus Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Chapter 4
UL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
European Communities (EC) Directive Compliance. . . . . . . . . . . . . . . . 51
FCC, IC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Appendix A
General and Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 55
Wireless Network Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Index
Rockwell Automation Publication 1425-UM001A-EN-P - January 2012 3
Table of Contents
Notes:
4 Rockwell Automation Publication 1425-UM001A-EN-P - January 2012
Preface
The information in this manual applies to the PowerMonitor W250 wireless
power monitor.
Additional Resources
These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Product Certifications website, http://www.ab.com
Provides general guidelines for installing a Rockwell
Automation industrial system.
Provides declarations of conformity, certificates, and
other certification details.
You can view or download publications at
http:/www.rockwellautomation.com/literature/
. To order paper copies of
technical documentation, contact your local Allen-Bradley® distributor or
Rockwell Automation sales representative.
Rockwell Automation Publication 1425-UM001A-EN-P - January 2012 5
Preface
Notes:
6 Rockwell Automation Publication 1425-UM001A-EN-P - January 2012
PowerMonitor W250 Unit Overview
Chapter 1
About the PowerMonitor W250 Unit
The PowerMonitor W250 product family provides a cost-effective, wireless submetering solution for use with RSPower™, version 5.0 or later, data visualization
and RSEnergyMetrix™, version 1.9 or later, energy monitoring, load profiling,
and reporting software. The PowerMonitor W250 family includes a selection of
power monitors, receivers, and routers that communicate wirelessly in a mesh
arrangement designed for robust, reliable energy data collection.
Figure 1 - Wireless PowerMonitor W250 System Overview
Rockwell Automation Publication 1425-UM001A-EN-P - January 2012 7
Chapter 1 PowerMonitor W250 Unit Overview
The PowerMonitor W250 unit consists of three main parts:
• Wireless power monitor: The PowerMonitor W250 unit is a sub-meter
that measures and calculates several electrical parameters. The unit is
equipped with pre-wired split core current transformers or Rogowski coils
and embedded wireless data transmission capabilities.
Figure 2 - Wireless Power Monitor
• Wireless PC Receiver: The receiver is a standalone gateway that manages
the wireless network and collects data periodically sent by PowerMonitor
W250 units. The receiver transmits data through its serial port to the data
logging system for analysis. An optional, user-provided serial to Ethernet
converter connects the receiver to your local area network.
Figure 3 - Wireless PC Receiver
8 Rockwell Automation Publication 1425-UM001A-EN-P - January 2012
PowerMonitor W250 Unit Overview Chapter 1
PowerMonitor W250 Unit with Current Transformers (CT)
PowerMonitor W250 Unit with Rogowski Coils
1
2
3
4
5
6
5
• Wireless router: The router is a repeater that extends the distance of the
wireless transmission range and can provide multiple signal paths between
the PowerMonitor W250 unit and the receiver when needed.
Figure 4 - Wireless Router
PowerMonitor W250 Unit
The PowerMonitor W250 unit is a 3-phase electric meter with wireless
communication. The following illustration highlights its major components.
Table 1 - PowerMonitor W250 Major Components
Item Description
1. Status indicator - Operation of the status indicator is described on page 31
2. Antenna location
3. DIN-rail mounting fixture
4. Product identification label Identification
5. Current transformer (CT) or Rogowski coil
6. Voltage input terminals
Figure 5 - PowerMonitor W250 Unit
.
Rockwell Automation Publication 1425-UM001A-EN-P - January 2012 9
Chapter 1 PowerMonitor W250 Unit Overview
PowerMonitor W250 Data Overview
The PowerMonitor W250 unit sends data to the wireless receiver periodically.
The meter data is split into three sections:
• Cumulative Energy Consumption Metering Data: The power monitor
transmits accumulated real, reactive, and apparent energy, per-phase and
total, once per minute. The transmission is accompanied with the time
stamp of the most recent reading.
• Interval Metering Data: The power monitor sends, at the end of the userselected interval, a time-stamped record of the following data: real,
reactive, and apparent energy per phase and sum; minimum voltage per
phase and maximum current per phase during recording interval;
frequency.
• Node Identification, Configuration, and Status: Node configuration and
version; recording interval time setup, command and status word.
PowerMonitor W250 Model Description
The following table lists the available models of the PowerMonitor W250 unit.
Table 2 - Model Description
Cat. No. Description Current
Rating (A)
1425-D1002-MOD PowerMonitor Wireless, 100A, 300V Delta 100 300 Delta, 3 W CT 111
1425-D1002-MOD-480 PowerMonitor Wireless, 100A, 480V Delta 100 480 Delta, 3 W Rogowski Coil 111
1425-W1003-MOD PowerMonitor Wireless, 100A, 300V Wye 100 300 Wye, 4 W CT 000
1425-D2002-MOD PowerMonitor Wireless, 200A, 300V Delta 200 300 Delta, 3 W CT 111
1425-W2003-MOD PowerMonitor Wireless, 200A, 300V Wye 200 300 Wye, 4 W CT 000
1425-D5002-MOD PowerMonitor Wireless, 500A, 300V Delta 500 300 Delta, 3 W CT 111
1425-D5002-MOD-480 PowerMonitor Wireless, 500A, 480V Delta 500 480 Delta, 3 W Rogowski Coil 111
1425-W5003-MOD PowerMonitor Wireless, 500A, 300V Wye 500 300 Wye, 4 W CT 000
1425-D10002-MOD PowerMonitor Wireless, 1000A, 300V Delta 1000 300 Delta, 3 W CT 111
1425-W10003-MOD PowerMonitor Wireless, 1000A, 300V Wye 1000 300 Wye, 4 W CT 000
1425-D20002-MOD PowerMonitor Wireless, 2000A, 300V Delta 2000 300 Delta, 3 W CT 111
1425-D20002-MOD-480 PowerMonitor Wireless, 2000A, 480V Delta 2000 480 Delta, 3 W Rogowski Coil 111
1425-W20003-MOD PowerMonitor Wireless, 2000A, 300V Wye 2000 300 Wye, 4 W CT 000
(1) Maximum voltage on sensing terminals must not exceed the following:
a.300V Delta, 3 W: 300V AC line-to-line maximum
b.300V Wye, 4 W: 300V AC line-to-neutral maximum
c.480V Delta, 3 W: 520V AC line-to-line, 300V AC line-to-neutral maximum
Max
Volt age
Delta/Wye Current
(1)
Sensing
Model
Code
10 Rockwell Automation Publication 1425-UM001A-EN-P - January 2012
PowerMonitor W250 Unit Overview Chapter 1
4
2
1
3
Wireless Mesh Network Components
The PowerMonitor W250 unit communicates by using a wireless mesh network,
capable of forming multiple paths in order to increase the robustness of the
network and respond to dynamic radio environments that may obstruct radio
transmission. In general, mesh network nodes are positioned at the point of
sensing and control to eliminate or minimize wiring. The PC Receiver is the
gateway between the wireless mesh network and RSEnergyMetrix software or
other client application. The wireless router extends the range of mesh network
nodes to accommodate long distances between PowerMonitor W250 units,
overcome physical barriers, and provide for multiple routing.
Wireless PC Receiver Overview
The wireless PC Receiver acts as a gateway that manages the wireless
communication network, and collects data from, and transmits control
commands to, the PowerMonitor W250 units that are members of the network.
Table 3 - Wireless PC Receiver and Accessories
Cat. No. Description
1425-GAT10 PowerMonitor Wireless PC Receiver, 10 Nodes
1425-GAT100 PowerMonitor Wireless PC Receiver, 100 Nodes
1425-GAT200 PowerMonitor Wireless PC Receiver, 200 Nodes
1425-ADR1 PowerMonitor Adapter, US
1425-ADR2 PowerMonitor Adapter, EMEA
1425-ADR3 PowerMonitor Adapter, UK
Physical features of the wireless PC Receiver unit are listed below.
Table 4 - PC Receiver Features
Item Description
1. Status indicators
2. Power supply connector 6…30V DC
3. RS-232/485 DB-9F connector
4. Internal push button (accessible with a < 1 mm rod, such as an unbent paper clip)
Figure 6 - PC Receiver
Rockwell Automation Publication 1425-UM001A-EN-P - January 2012 11
Chapter 1 PowerMonitor W250 Unit Overview
2
3
1
Table 5 - PC Receiver Status Indicators
Indicator Position Status Description
Power Left Green ON Power OK
OFF Power has been removed
Communication Middle Green ON Modbus mode
Amber ON Standard (MASC) mode for Meshscape Network Monitor or
Meshscape programmer use
Red ON Programming in progress
RF activity Right Green ON Initialization, PC Receiver not operating
Flashing Green RF activity
Wireless Router Description
The Wireless Router extends the range of the mesh network to accommodate
longer distances between nodes, overcome physical barriers, and provide for
multiple signal routing.
Table 6 - Wireless Router and Accessories
Cat. No. Description
1425-NOD Wireless Power Monitor Router
1425-ADR1 PowerMonitor Router Adapter, US
1425-ADR2 PowerMonitor Router Adapter, EMEA
1425-ADR3 PowerMonitor Router Adapter, UK
Table 7 - Wireless Router Features
Item Description
1 Status indicators (see Tab le 8)
2 Power supply connector 6…30V DC
3 Connector panel access cover (ON/OFF switch)
Figure 7 - Wireless Router
12 Rockwell Automation Publication 1425-UM001A-EN-P - January 2012
PowerMonitor W250 Unit Overview Chapter 1
Table 8 - Wireless Router Status Indicators
Indicator Status Description
PWR ON Power ON.
OFF No power.
RF Activity Flashing Router detects RF activity. The RF activity indicator will flash
OFF No RF activity detected.
STS ON Solid Green Device has established two or more connections with other
Blinking The router has established a single connection; additional
OFF The router is not on the network: additional routers are
when detecting valid packets (packets destined for device)
and may also flash when detecting invalid packets (packets
destined for other devices) or environmental noise. Only
valid packets are processed by the device.
devices.
routers may be needed to increase robustness.
needed for this device to connect to the network.
Wireless Network Description
The PowerMonitor W250 unit communicates with the PC Receiver node by
using a self-configuring, wireless mesh network. Node IDs (addresses) are
programmed at the factory and usually do not need to be changed. Please contact
Rockwell Automation for assistance if you need to change the node ID of a
device.
In a wireless mesh network, messages may be received and retransmitted by
several devices, depending on the design and layout of the network. Each wireless
retransmission between the power monitor and the PC Receiver through one or
more Routers is called a ‘hop’. When operating, the network automatically selects
the path with the least hops through routers if it is available.
Strategies to design the wireless network to increase robustness and overcome
challenges presented by the environment are discussed in Chapter 2
, Hardware
Installation.
Each PowerMonitor W250 unit and the PC Receiver are equipped with a radio
module. The PC Receiver buffers in its RAM the metering values received from
the power monitors. The measurement values of the PowerMonitor W250 unit
are buffered in the PC Receiver's RAM.
When a Modbus master station reads data from PowerMonitor W250 registers,
it reads the buffered values from the PC Receiver.
However, when a Modbus master station transmits a command to a power
monitor, the command is forwarded to the power monitor. A delay of 2…4
minutes may occur until the PC Receiver transmits the response message.
Rockwell Automation Publication 1425-UM001A-EN-P - January 2012 13
Chapter 1 PowerMonitor W250 Unit Overview
Notes:
14 Rockwell Automation Publication 1425-UM001A-EN-P - January 2012
Safety Considerations
Chapter 2
Hardware Installation
This chapter describes how to install the hardware to set up the Wireless Mesh
Sub-meter Network.
ATT EN TI ON : Only qualified personnel, following accepted safety procedures,
should install, wire and service the PowerMonitor W250 unit and its associated
components. Before beginning any work, disconnect all sources of power and
verify that they are de-energized and locked out. Failure to follow these
instructions may result in personal injury or death, property damage, or
economic loss.
This equipment is designed to be installed in an enclosure with access restricted to
qualified personnel. Installation is to be performed in accordance with all
applicable codes, regulations, laws, and standards.
Before You Begin
• The equipment must be installed in an appropriate enclosure to provide
protection to personnel and is suitable for the physical installation
environment.
• Do not remove or change any part of the product, or cut any cables, as
doing so may damage it or other equipment or cause serious injury or
death.
• If the equipment or any part of it is damaged, do not install it. Remove and
replace any damaged equipment.
• Check carefully that the PowerMonitor W250 model received is
appropriate for the system to be monitored. Otherwise, wrong or
incomplete data may be sent to the wireless PC Receiver.
• Carefully read this manual and observe any notes, cautions, or warnings.
Rockwell Automation Publication 1425-UM001A-EN-P - January 2012 15
Chapter 2 Hardware Installation
IMPORTANT
Network Deployment Recommendations
Prior to defining your network and the elements location, read the following
information.
We recommend you apply power to the Wireless PC Receiver before applying
power to the PowerMonitor W250 unit or Router nodes.
ATT EN TI ON : All devices are designed for indoor use only.
Planning Your Installation
Follow this information before installing your PowerMonitor W250 unit.
Building Audit
Mesh devices all communicate via wireless radio frequencies and are influenced
by several factors (electrical wires, metal objects, heavy concrete walls, direction
of installed devices, and so on).
Consider the following items in network configuration:
• Number of floors, layout
• Network topology - dense versus spread out/serial
• Typ e o f b uil di ng ma teri al
• Power availability for routers and receivers not attached to meters
• Any known obstacles or RF interferences (for example, heating pipes,
electrical room)
• ‘Bridge’ router placement
• Detect other 2.4 GHz interference
Walls and Floors
Inside a building, radio waves deflect on walls and other objects create
interference.
When the PowerMonitor W250 unit or other system components are mounted
on a wall or where the RF signal travels through a wall or other construction, be
aware of the materials used in the construction (both sides). Note that certain
materials will reduce the signal strength and maximum distance between nodes.
Usually, floors are most difficult for radio frequency signals to penetrate due to
materials used (for example, concrete, cement, and tiles). So, consider placing
routers in stairways and other open spaces available between floors.
16 Rockwell Automation Publication 1425-UM001A-EN-P - January 2012
Hardware I nstallation Chapter 2
Effect of Different Materials on Signal Strength and Maximum Node-to-node Distance
Glass, sheet rock, and wood have the least impact to the RF signal.
Steel-reinforced concrete, brick walls, and corrugated steel surfaces are much
more difficult for the RF signal to penetrate. The maximum node-to-node
distance could be cut in half compared to the unobstructed maximum distance.
In any case, the maximum distance between two nodes depends on the geometry
of the signal path and the number, thickness, and composition of any
obstructions.
Metal blocks virtually all radio communication. RF transmission through metal
is facilitated by openings (slits, holes, and gaps) in the metal.
Network Topologies
The robustness and reliability of communication between PowerMonitor W250
devices and RSEnergyMetrix software or other clients depends primarily on
network RF signal strength. In turn, RF signal strength is dependent upon the
topology of the network. In general, a mesh network topology that provides
parallel links between devices provides better RF signal strength resulting in
more robust communication. Linear topologies that offer only a single path from
device to client can create bottlenecks that reduce effective RF signal strength
and adversely impact communication robustness. You may add more routers to a
network topology to accommodate longer distances or add parallel routes
through the network in areas that present a challenging environment.
Preferred Network Topology
An ideal network topology is ‘Star-Mesh’, where all nodes are evenly distributed
from the PC Receiver and offer multiple, parallel communication links.
In such a configuration, all devices can communicate with multiple nodes, so that
if one router fails or if a radio link experiences interference, the network will
reconfigure itself through the remaining nodes. Having multiple routes to the
gateway will also improve the estimated sampling rate.
Rockwell Automation Publication 1425-UM001A-EN-P - January 2012 17
Chapter 2 Hardware Installation
Figure 8 - Star Mesh Topology (Best)
Alternative Topologies
The network topologies shown below are not as robust as the Star Mesh
topology. However, for simple installations within an environment that is
favorable, these topologies may provide acceptable network performance.
Figure 9 - Linear Topology (Good)
Figure 10 - Star Topology (Better)
18 Rockwell Automation Publication 1425-UM001A-EN-P - January 2012
Hardware I nstallation Chapter 2
Constricted Topology: Not Recommended
In some cases, PowerMonitor W250 devices might be located far away from the
PC Receiver and all data from the network has to travel over a single path. Such a
situation creates bottlenecks and increases the risk of losing data packets.
We recommend avoiding such topologies by adding additional routers to provide
parallel links to the PC Receiver.
Figure 11 - Constricted Topology
PM
W250
RTRRTR RTR
RTR
PCR
PM
W250
Bottlenecks
PC Receiver Location and Connection
Consider these suggestions when locating your PC Receiver:
• When possible, locate the PC Receiver near the geographical center of the
RF network.
• It may be helpful to have a notebook personal computer for startup,
diagnostics, and troubleshooting.
Follow these steps to connect the PC Receiver.
1. Apply power to the PC Receiver by plugging in the DC power supply
adapter.
We recommend that you apply power to the PC Receiver prior to applying
power to any PowerMonitor W250 devices.
Rockwell Automation Publication 1425-UM001A-EN-P - January 2012 19
Chapter 2 Hardware Installation
TIP
2. Connect the PC Receiver's data port (DB-9F connector) to the serial port
of a host computer, a serial to Ethernet converter, or similar device.
To connect to a USB port, the Allen-Bradley 9300-USBS USB to serial
adapter (or equivalent) is recommended. Please contact your local
Rockwell Automation representative for more information.
Figure 12 - Connect the PC Receiver Data Port to the Personal Computer
Router Location and Connection
Router location and orientation is important. The router is designed to be
mounted horizontally. The radio antenna, on the router, transmits in a
horizontal, circular pattern when the signal path is not obstructed. The following
guidelines help you locate router devices to attain acceptable radio signal strength
and system performance:
• It is best to mount routers in a horizontal orientation. It is less desirable,
but acceptable, to orient one router horizontally and another vertically. It
is not recommended to orient all routers vertically, unless doing so
intentionally to route the radio signal vertically through a stairway, chase,
or elevator shaft.
• Mount power monitors in a vertical orientation.
• Avoid locating a router directly underneath a PowerMonitor W250 device.
The internal electronic circuitry in the power monitor may obstruct the
radio signal.
• Avoid installing routers directly onto a horizontal metal surface. Use
spacers to create a free space of 3…5 mm between the router and the metal
surface.
• When the radio signal must penetrate an obstruction such as a concrete
wall, locate network devices (routers and/or power monitors) on opposite
sides of the wall to create a short, direct signal path. Signal loss may occur if
a long path exists through an obstruction.
See Figure 13
20 Rockwell Automation Publication 1425-UM001A-EN-P - January 2012
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