Onicon System-10 BTU Meter User manual

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System-10 BTU Meter
MODBUS RTU Network Interface Installation Guide
07-18
MODBUS
0653-13 / 18321
ON I CON
Flow and Energy Measurement

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TABLE OF CONTENTS
1.0 INTRODUCTION ..................................................................................................5
1.1 PURPOSE OF THIS GUIDE .......................................................................5
1.2 TYPICAL SYSTEM-10 BTU METER.........................................................5
1.3 SPECIFICATIONS ......................................................................................5
1.4 NETWORK SIGNAL CONNECTIONS.......................................................6
1.4.1 RS485...............................................................................................6
1.4.2 TCP/IP .............................................................................................7
1.4.3 Optional Network Interface with
Isolated Digital Pulse Input (Di3) ...................................................8
1.5 RS485 BAUD RATE, BIASING AND TERMINATION............................11
1.5.1 Baud Rate ......................................................................................11
1.5.2 Biasing and Termination...............................................................12
1.6 NETWORK ADDRESSING.......................................................................12
1.6.1 Changing the MAC (Device) Address...........................................12
1.6.2 Changing the IP Address ..............................................................14
1.6.3 Changing the Gateway Address....................................................16
2.0 MODBUS MEMORY MAP..................................................................................19
2.1 MODBUS REGISTER FORMAT AND
NETWORKING INFORMATION .............................................................19
2.2 MODBUS MEMORY MAP ......................................................................20
2.3 TOTALIZATION, RESETTING TOOLS AND OVER-RANGE
AND ROLLOVER .....................................................................................26
3.0 NETWORK TROUBLESHOOTING TIPS ...........................................................28
3.1 TROUBLESHOOTING .............................................................................28
APPENDIX
A-1 SYSTEM-10 BTU COMPUTER BOARD
A-2 SYSTEM-10-MOD BTU METER MODBUS RTU RS485 BOARD
A-3 SYSTEM-10-MOD BTU METER MODBUS TCP BOARD
A-4 SYSTEM-10-MOD BTU METER MODBUS TCP/IP AUXILIARY INPUT BOARD

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SECTION 1: INTRODUCTION
1.1 PURPOSE OF THIS GUIDE
The purpose of this guide is to provide installation procedures and basic operating and servicing
instructions for the ONICON System-10 MODBUS RTU serial interface.
1.2 TYPICAL SYSTEM-10 BTU METER
ONICON’S System-10 is a true heat (Btu) computer, which accepts data from several sensors,
performs a series of computations with that data, and displays and/or transmits the results as an
indication of the amount of heat (Btu’s) being transferred per unit time or as a totalized amount.
1.3 SPECIFICATIONS
MODBUS RTU NETWORK INTERFACE
RS485
Transceiver: 2-wire, half-duplex
Data format: 8 bit with 1 stop bit
Parity: None
MAC address (device address) range: 1 - 247 (Default: 017)
Baud rate: 1200, 2400, 4800, 9600, 19200, 38400, 57600 or 115200 (Default: 9600)
Termination: 120 ohms or none (Default: none)
Biasing: None
Flow control: None
TCP/IP
Transceiver: 10Base T, 10Mbps, Rj45 connection
Data format: 8 bit with 1 stop bit
Parity: None
MAC address (device address) range: 1 - 247 (Default: 017)
Default IP address: 192.168.1.24 (Port 502)
Flow control: None
Heat Exchanger
SCRO LL RESET PROG RAM
BTU X 10,000
ONICON insertion
flow meter (purchased
separatelly)
24 VAC input
MODBUS RTU
Communications to
Network
Supply Temp
Sensor
Return Temp
Sensor
Supply
Return
SYSTEM-10
BTU METER

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CAUTION
Only qualied service personnel should make connections between the System-10 BTU Meter
and the user’s external equipment. ONICON assumes no responsibility for damage caused to
the external equipment as a result of an improper installation.
!
Terminal
T1
Do not connect
shields to this
terminal.
CAUTION
Incoming and outgoing RS485 cable shield wires should be connected together, but must not be
connected to the Btu meter.
!
1.4 NETWORK SIGNAL CONNECTIONS
1.4.1 RS485
MODBUS RS485, 2-wire (half-duplex) serial output connections are connected to terminal
T1 as shown. Do not exceed 4.4 in-lb (0.5 Nm) of torque when tightening.

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1.4.2 TCP/IP
MODBUS TCP, 10Base T output connections are made as shown. Requires 10Base T cable
and Rj45 connector.
!
CAUTION
Only qualied service personnel should make connections between the System-10 BTU Meter
and the user’s external equipment. ONICON assumes no responsibility for damage caused to
the external equipment as a result of an improper installation.

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1.4.3 Optional Network Interface With Isolated Digital Pulse Input (Di3)
The System-10 BTU Meter can be provided with an auxiliary pulse input for totalizing
pulse outputs from external devices such as water or gas meters. Pulses are accumulated
in an internal register, and the totalized value is available on the network. This register
can be zeroed via the network. The maximum register total is 9,999,999. The register will
rollover to zero when this value is exceeded.
If the auxiliary pulse input option was ordered at the same time the BTU Meter was
ordered, it will arrive fully congured and ready to use. If it was ordered after the BTU
Meter was delivered and is being installed as a eld upgrade, it may be necessary to
congure the pulse input. The information required to congure the input is provided
below and on the following pages:
The input pulse must meet the following criteria:
1. Frequency input range, 50 Hz maximum
2. 10 millisecond minimum pulse duration
Input Pulse Denition:
In order to congure the communications card auxiliary pulse input, you must rst
determine which type of pulse your meter produces. The allowable types of input
pulses are described on the following pages. Based on the type of pulse, set the selector
switch (S1) on the communications circuit board (Fig. 1) to the correct setting.
Fig. 1
120 ohm Jumper Selectable
Termination Resistor
Pulse Type Selector Switch (S1)
Input Impedance Jumper (J1)
Aux Pulse Input (Di3) Connector (T2)
RS485 Connector (T1)
NOTE: MODBUS RS485 shown above. See appendix A-4 for MODBUS TCP/IP auxiliary input board.

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Powered Pulse:
This type of output refers to a pulse which has an associated voltage with it (see Fig. 2).
Set the selector switch, S1 to Pwrd Pulse. The allowable voltage range is 5-24 VDC. The
input impedance is set at the factory to be 11 KOHM via the impedance selector jumper
(J1, see Fig. 1). A lower impedance, 3 KOHM can be selected if required by the instrument
providing the pulse output. Consult the instrument manufacturer or ONICON if you are
uncertain as to the proper jumper selection.
Fig. 2
Open Collector (Sourcing):
This type of output refers to an open Collector Switch congured for a sourcing function
(see Fig. 3). Set the selector switch, S1 to SRC. The switch must be rated for at least 20 mA
at 20 VDC.
Fig. 3
Di3 In (+)
Di3 In (-)
Di3 In (+)
Di3 In (-)
ONICON BTU
Meter
ONICON BTU
Meter
Pulse Switch and Jumper Location

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Open Collector Sinking or Dry Contact:
This type of output refers to an open collector switch congured in a current sinking
arrangement or a dry contact switch (see Fig. 4 and 5). Set the selector switch, S1 to Sink.
In either case, the switch must be rated for at least 20mA at 20 VDC.
Fig. 4
Fig. 5
Di3 In (+)
Di3 In (-)
Di3 In (+)
Di3 In (-)
ONICON BTU
Meter
ONICON BTU
Meter

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1.5 RS485 BAUD RATE, BIASING AND TERMINATION
1.5.1 Baud Rate
Every ONICON System-10 is individually programmed at the factory with application
specic data provided by the customer during the process of ordering the Btu meter. This
normally includes the Baud rate setting. If the Baud rate was provided, the Btu meter will
be congured to operate at the specied rate. The available Baud rate settings are listed in
the table below.
If the Baud rate setting was not provided to ONICON, the Btu meter will be congured
to 9600.
The Baud rate setting can be manually changed in the eld. The drawing and table
below show the Baud rate dipswitch settings.
BAUD Rate B1 B2 B3 B4
9600 OFF OFF OFF OFF
1200 ON OFF OFF OFF
2400 ON ON OFF OFF
4800 ON OFF ON OFF
9600 ON ON ON OFF
19200 ON OFF OFF ON
38400 ON ON OFF ON
57600 ON OFF ON ON
115200 ON ON ON ON
Baud Rate Dip Switches
ON

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1.5.2 Biasing and Termination
The ONICON System-10 BTU Meter does not provide biasing voltage to the RS485
network. A jumper selectable 120Wresistor is provided as show below. The termination
resistor should only be used when the meter is installed at the end of the line.
NOTE: See Fig. 1 on page 8 to locate the termination resistor on network interface board
with auxiliary input.
Jumper selectable
120 Ohm resistor
1.6 NETWORK ADDRESSING
Before the System-10 can communicate on the MODBUS network, the appropriate device address
must be programmed into the meter. For TCP/IP networks an IP address must also be assigned
to the Btu meter.
The MODBUS network address for ONICON System-10 Btu meter may be set to any address from
001 to 247 in compliance with the MODBUS standard. This address is set at the Btu meter.
Section 1.6.1 details the procedure for changing this address.
MODBUS TCP/IP Btu meters also require an IP address to operate on the network. In addition,
managed TCP/IP networks may require a gateway address. The procedures for entering the IP
address and gateway address are detailed in sections 1.6.2 and 1.6.3. Both require the use of the
RUInet utility program and a PC with an Ethernet card and an available port.
1.6.1 Changing the MAC (Device) Address
Every ONICON System-10 is individually programmed at the factory with application
specic data provided by the customer during the ordering process, and this may include
network addressing information. If the device address information was provided, the
meter will be programmed with that number. If no address is provided, ONICON
meters are programmed with a default address of 017. The address may be changed at
the System-10 using the procedure outlined in the table on the next page.

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STEP ACTION REACTION COMMENT
0 Obtain a device address from the
network administrator.
The device address is a three
digit number between 001-247,
excluding zero.
1 With the display running, open the
front panel and locate switch DEV
ADD/PROG ENAB. Press DEV ADD/
PROG ENAB and then release it.
None The DEV ADD/PROG ENAB is
located in the lower left corner
of the processor board.
(See appendix page A-1.)
2 Close the front panel.
3
Press the PROGRAM button. (If you
do not press the PROGRAM button,
the display will revert to the RUN
mode after 5 minutes.)
The Btu meter changes to
PROGRAM mode and the
DEVICE ID page will appear
with the rst digit of the
address ashing.
The PROGRAM button is on
the front panel.
4
Successively press the SCROLL
button to increment the number to
the desired value from 0-9.
The number increments by
one each time you press the
button.
The SCROLL button is on the
front panel.
5 Press the RESET button. The second character blinks. The RESET button is on the
front panel.
6
Successively press the SCROLL
button to increment the number to
the desired value from 0-9.
The number increments by
one each time you press the
button.
The SCROLL button is on the
front panel.
7 Press the RESET button. The third character blinks. The RESET button is on the
front panel
8
Successively press the SCROLL
button to increment the number to
the desired value from 0-9.
The number increments by
one each time you depress the
button.
The SCROLL button is on the
front panel.
9
Once the correct address is displayed,
momentarily press the PROGRAM
pushbutton.
The FM LOCN page appears
with UNKNWN defaulted as
the current location.
The PROGRAM button is on
the front panel.
10 Press the SCROLL button.
The setting will toggle
between UNKNOWN,
SUPPLY, and RETURN.
Refer to Section 4.5 of the
System-10 Installation and
Operation Guide if you with to
change settings.
11 Press the PROGRAM button. The FRONT PANEL
RESET page appears.
It is not necessary to change
anything on this page.
12 Press the PROGRAM button. The SAVE CHANGES page
appears.
The new device address must
be saved to take effect.
13 Press the SCROLL button. The N changes to Y on the
SAVE CHANGES page.
The Y must be selected in
order for the new address to
take effect.
14 Press the PROGRAM button.
The new address is saved and
the display reverts to the RUN
mode.
15
Open the front panel and locate the
RESET switch. Press to reset the
System-10.
When polled, the System-10
will automatically begin to
communicate with the
network.
RESET is located along the top
of the processor board.
(See appendix page A-1.)

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1.6.2 Changing the IP Address
Changing the IP Address requires the use of RUInet utility software and a PC with an
Ethernet card and an available port. Assuming the Btu meter is programmed with the
default IP address (192.168.1.24), the host PC must be congured with an IP address of
192.168.1.1 and a subnet mask of 255.255.255.0. RUInet is available for download from the
ONICON website, http://www.onicon.com/Networking_Information.html.
1. Load RUInet and congure the PC as necessary.
2. Connect an RJ45 Ethernet cable between the PC and the System-10 and power the
meter. Allow 60 seconds for the System-10 rmware to cycle through start-up
diagnostic routines.
3. Open RUInet.
4. From the Remote User Interface main menu (shown below) select option
“I”, Change IP Address.
5. From the Edit IP Address Settings menu (shown below) select option 1. Please
note that the default subnet mask is 255.255.255.0 and should not be changed
unless necessary.

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6. Enter the new IP address as shown below and press enter.
7. The following message will appear.

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8. When the address change is complete, the following message will appear.
You must cycle power to the System-10 for the change to take effect.
1.6.3 Changing the Gateway Address
Changing the gateway address requires the use of RUInet utility software and a PC with
an Ethernet card and an available port. Assuming the meter is programmed with the
default IP address (192.168.1.24), the host PC must be congured with an IP address of
192.168.1.1 and a subnet mask of 255.255.255.0. RUInet is available for download from the
ONICON website, http://www.onicon.com/Networking_Information.html.
1. Load RUInet and congure the PC as necessary.
2. Connect an RJ45 Ethernet cable between the PC and the display and power the
System-10. Allow 60 seconds for the display rmware to cycle through start-up
diagnostic routines.
3. Open RUInet.
4. From the Remote User Interface main menu (shown below) select option “I”,
Change IP Address.

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5. From the Edit IP Address Settings menu (shown below) select option 3.
6. Enter the new gateway address as shown below and press enter.

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7. The following message will appear.
8. When the address change is complete, the following message will appear. You
must cycle power to the System-10 for the change to take effect.

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SECTION 2.0: MODBUS MEMORY MAP
ONICON Btu meters equipped with MODBUS serial communications provide energy and volume rate
data, and totalized energy and volume data in a variety of engineering units. You select the engineering
units you wish to use by mapping to the appropriate registers.
Also supplied with your System-10 is a document titled “Recommended MODBUS Conguration
Data”. This document is different for each Btu meter. It provides a suggested list of registers to use. The
recommendations are based on the calibration of the ow meter and the programming of units and
multipliers displayed on the System-10.
2.1 MODBUS REGISTER FORMAT AND NETWORKING INFORMATION
1. All registers are 16 bit MODBUS Holding Registers.
2. MODBUS Holding Registers are used in 4 different ways.
A. As an Analog Value: In some cases these values are scaled
by multiplying the register contents by a xed multiplier.
B. As a status indicator where the register value can only
be “1” or “2”.
C. As a mode indicator where the value indicates current operating mode
such as “1” = single, “2” = dual, or “3” = bi-directional.
D. As a control register where the host can write a value to reset total(s).
3. Registers 40001 through 40068 are unsigned integer registers (0 to 65,535) except for 40024
and 40025. These are 16 bit signed integer values (-32,768 to +32,767). Registers 41003
through 41081 are 32 bit single precision oating point values. 41001, 41002 and 41065
through 41069 are unsigned integer registers.
4. System-10 MODBUS register addresses are formatted as follows:
Example: address 40001
4= Holding register
0001 = Address that corresponds to memory location 0000
5. MODBUS function codes supported:
CODE DESCRIPTION
03 Read Holding Registers
06 Preset Single Registers
16 Preset Multiple Registers
17 Report Slave ID
i
IMPORTANT NOTE
ONICON provides data in integer and oating point format. We recommend the use of oating
point registers to transmit data to the network. The use of oating point data eliminates the need
for scaling and additional mathematical operations to totalize energy and ow.

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NETWORKING INFORMATION MODBUS RTU MODBUS TCP
Connection Information RS485, 2-wire half-duplex 10Base T, 10Mbps, RJ 45 Connection
Data format / Parity 8 bits, 1 stop bit / None 8 bits, 1 stop bit / None
Flow Control (handshaking) None None
Device Address Range 1 - 247 1 - 247
IP Address Not required Default address: 192.168.1.24
Termination (selectable) 120 W or none (default none) None
Biasing None None
2.2 MODBUS MEMORY MAP
Available Engineering Units
ENGINEERING UNITS ABBREVIATION
Energy Rate
Btu per hour Btu/Hr
Btu per hour x 1,000 kBtu/Hr
Btu per hour x 1,000,000 MBtu/Hr
Watts x 1,000 kW
Watts x 10,000 kW x 10
Tons Tons
Volume Rate (Flow)
Gallons per minute GPM
Gallons per minute x 10 GPM x 10
Gallons per hour GPH
Million gallons per day MGD
Liters per second L/S
Liters per minute L/M
Liters per hour L/H
Cubic meters per hour M³/Hr
Cubic meters per hour x 10 M³/Hr x 10
Cubic feet per second Ft3/S
Cubic feet per minute Ft3/M
Mass Rate (Mass ow) –
Only available with F-2000 Flow Meter
Pounds per hour Lb/Hr
Pounds per hour x 10 Lb/Hr x 10
Kilograms per hour kg/Hr
Kilograms per hour x 10 kg/Hr x 10
Temperature
Degrees Fahrenheit °F
Degrees Celsius °C
ENGINEERING UNITS ABBREVIATION
Energy Total
Btu x 1,000 kBtu
Btu x 1,000,000 MBtu
Btu x 1,000,000,000 GBtu
Ton-hours TonHr
Ton-hours x 1,000 kTonHr
Watt-hours x 1,000 kWHr
Watt-hours x 1,000,000 MWHr
Watt-hours x 1,000,000,000 GWHr
Volume Total
Gallons x 1,000 kGal
Gallons x 1,000,000 MGal
Gallons x 1,000,000,000 GGal
Liters x 1,000 kLiters
Liters x 1,000,000 MLiters
Liters x 1,000,000,000 GLiters
Cubic Meters M³
Cubic Meters x 1,000 kM³
Mass Total -
Only available with F-2000 Flow Meter
Pounds x 1,000 kLbs
Pounds x 1,000,000 MLbs
Kilograms x 1,000 Kkg
Kilograms x 1,000,000 Mkg