Cellular Network Interface (CNI) Models GSM18, GSM20 and CDMA18

Transcription

1 Cellular Network Interface (CNI) Models GSM18, GSM20 and CDMA18 AC- and DC- Powered Unit Assemblies with Cathodic Protection Monitor (CPM-1 or CPM-2) Option User s Guide Document: Revision: B September, 2006

2 WARNING This product contains a radio-frequency transmitter, Motorola Model g18, FCC ID # IHDT6AC1, Motorola Model g20, FCC ID # IHDT56DB1 or Motorola Model c18, FCC ID # IHDT56CW1. The combined cable loss and antenna gain must not exceed 6.1dBi gain, and the antenna installation must provide a minimum separation distance of 20cm (8 ) from users and nearby persons and must not be collocated or operating in conjunction with any other antenna or transmitter. See Chapter-7 for more safety information. WARNING No hazardous area safety approvals have been received for this product. It is therefore necessary to ensure that the product is only installed at locations that are classified as safe area sites. See Chapter-7 for more safety information. COPYRIGHT 2004, 2005, 2006 by Metretek, Incorporated All rights to this document, domestic and international, are reserved by Metretek, Incorporated. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise) without the prior written permission of Metretek, Incorporated. Requests for permission to reproduce or distribute this manual should be addressed to: METRETEK, INCORPORATED 305A EAST DRIVE MELBOURNE, FLORIDA, USA ii

3 COMMON QUESTIONS The Cellular Network Interface is simply referred to as the CNI throughout this document. These units are configured as legacy Metretek data collection devices known as a Cathodic Protection Monitors, or CPMs. What does this device do? The Cellular Network Interface (CNI), configured as a Cathodic Protection Monitor-1 (CPM-1) can digitize one or two analog signals as high a 150 Vdc with complete isolation. Another version, the Cathodic Protection Monitor-2 (CPM-2) can digitize up to eight external analog signals, control two external switches or relays, monitor one or two external switches and count pulses from an external device. The CPM-2 does not provide input isolation. At predetermined times the CNI establishes a radio link with a cellular telephone service provider and transmits its information to a central computer system for processing. On that computer is a sophisticated data collection program that can process calls from hundreds of devices per hour, process and organize the data, and issue new instructions to the devices when needed. The CNI and the data collection software are highly configurable. This system is often used to monitor and control electrical activity in metallic objects such as pipelines, towers or building structures. This galvanic activity often leads to corrosion and premature structural failure. Does the CNI use a cell phone? The cellular radio module is similar to that used in a digital cellular phone, but there is no display, keypad, speaker or microphone. Instead it has a communications port that allows the CNI to use the radio as a wireless modem. Also, the radio is designed for more severe environmental conditions than a commercial cell phone. There are references within this document to mobile devices because the cellular radio system was intended to support portable phones and equipment. Though the CNI is normally installed in a fixed location, it is still classified as a mobile device. How is the CNI packaged? All circuit boards and batteries are mounted within a fiberglass NEMA 4X rated enclosure. This enclosure has built-in mounting holes and a latch that can be locked. All exposed fasteners are made of stainless steel. This enclosure is designed for outdoor environments and can withstand wide variations in temperature and humidity. Does it matter where the CNI is installed? Since the CNI contains the equivalent of a cellular phone it has the same limitations with respect to metal buildings and sources of radio interference. Optional antenna kits are available that may overcome some of these problems. Also, and this is very important, although the equipment that will be attached to the CNI may be allowed to operate in hazardous areas, the CNI itself must not be installed in any area classified as hazardous. The use of safety barriers may be necessary. iii

4 Is the CNI ready to use immediately? No, there are six important steps required before the CNI can be put into service: 1) For AC-powered units power must be wired to the unit via a step-down transformer (Chapter-2). 2) Any external data and/or alarm devices must be wired to the unit (Chapter-2). 3) Cathodic rectifier site wiring connections must be made to the unit (Chapter-2). 4) You must purchase cellular phone service and activate the radio (Chapter-3). 5) You must configure the unit using a computer and a special program and cable from Metretek (Chapter-4). 6) The data collection software supplied by Metretek must be supplied with information about the CNI before it can communicate with the device (Chapter-5). How do I purchase cellular service? As with any cellular phone, you must purchase cellular service. There are several different digital technologies used today. When you purchase a personal cell phone you generally choose a provider that has the best calling plan and coverage in the area you live or work. You then receive a phone that works with their technology. The CNI is designed to support GSM or CDMA technology. Though all service providers support voice calls, not all of them may support the exchange of data. Therefore it is necessary to locate a service provider that supports circuit-switched data (CSD) connections or Internet connections using the general packet radio standard (GPRS) for GSM service, or single carrier, radio transmission technology (1X or 1XRTT) packet service for CDMA. Chapter-3 will help with this process. Why must the CNI be configured? When the CNI places a data call it must have a phone number to dial, instructions about what to do if the line is busy, etc. Each CNI must also be assigned a unique ID number so that the data collection software can identify it. These parameters must be programmed into the unit prior to its first operation. The CNI is configured using your computer and a special cable and software supplied by Metretek. This can be done any time before, during or after installation. Chapter-4 provides additional information. What does the data collection software do? Metretek s Cathodic Protection Monitor (CPM) data collection software has the ability to process calls from hundreds of devices. Each CNI can be scheduled to call in at specific times throughout the day, or once a week or once a month. In some cases the data collection software can call the CNI. The data collection software can process the information in many different ways, depending upon the customer s needs. It can also notify you immediately when an alarm condition occurs. To do this properly each CNI must be registered with the software. The meaning and nature of each analog input can be defined, and alarm conditions can be enabled or disabled. Chapter-5 has much more information. iv

5 What is the difference between CSD and Packet Service? When the CNI places or receives a CSD (circuit-switched data) call, it will be communicating with an analog modem that is tied to a wired telephone line at the central computer site. The cellular service provider has banks of modems available in its switching centers. When it detects a CSD call it connects one of its own modems to the wired line. Data is transferred between the CNI and the switching center over the radio link, and then between the switching center and the destination modem via wire. Like a voice call, a CSD call is generally billed by the minute. Some service providers may only support mobile-originate calls, meaning the CNI can place a call but cannot be called. GSM cellular service providers may offer access to the Internet using a service called GPRS (general packet radio service). CDMA cellular service providers may offer access to the Internet using a service called 1X or 1XRTT (single carrier, radio transmission technology). Data is exchanged in small blocks, or packets, with the Metretek data collection software. A packet call is generally billed by the amount of data exchanged per month rather than by the minute. Packet service has the advantage of being able to retrieve data from any CNI regardless of how far away the unit is from the central computer, without the expense of long-distance phone calls. v

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7 TABLE OF CONTENTS 1 PRODUCT DESCRIPTION Product Overview Wireless Data Collection Concept Communications Scenarios Packet versus Circuit Switched Data (CSD) Service INSTALLATION AND TECHNICAL INFORMATION Unpacking, Damage Reports, Item List Additional Items Required for Installation Enclosure Dimensions and Site Selection Technical Information about the CPM CPM-1 Power Options Layout of a Single-Channel CPM Layout of a Dual-Channel CPM-1 without Inter-Channel Isolation Layout of a Dual-Channel CPM-1 with Inter-Channel Isolation Internal Wiring of a Dual-Channel, AC-Powered CPM Internal Wiring of a Dual-Channel, DC-Powered CPM Internal Wiring of a Single-Channel CPM ILI Board Layout Power Requirements Analog Signal Voltage Range How the ILI Board Works Wiring External Devices to the CNI s Communications Port Optional RS-232 Dual-Port Multiplexer Direct Connection of the Multiplexer Board Technical Information about the CPM Internal Components of the AC-Powered CPM Internal Wiring of the CPM Wiring to the Pulse / Alarm Inputs RS-232 Serial Data Port MCM-II Board Layout Circuit Board Jumpers Terminal Block Circuit Connections Cathodic Rectifier Wiring to MCM-II Determining the Rectifier s Configuration Configuring the MCM-II Jumpers Rectifier Connections to the MCM-II Board Reference Cell Connections Special Connection Options Relay Outputs Component Common to Both the CPM-1 and CPM AC Power Supply Board AC Mains Power Supply Connection DC Power Supply Board Installing or Replacing the Rechargeable Battery Model GSM18 CNI Board Layout Model GSM20 CNI Board Layout Model CDMA18 CNI Board Layout CNI Board Block Diagram vii

8 2.7 CNI Board Jumper Settings Internal Antennas External Antenna Kit Lead Acid Battery Testing / Replacement Cycle Lithium Battery Testing / Replacement Cycle CELLULAR SERVICE GSM Service GSM Overview Establishing Cellular Service for GSM CSD SIM Card Installation for the GSM SIM Card Installation for the GSM Requesting a Voice Phone Number or SMS Service CDMA Service CDMA Overview Establishing Cellular Service for CDMA CSD Requesting a Voice Phone Number or SMS Service Over-the-Air Activation CONFIGURATION USING METRETEK PROGRAMMER Metretek Programmer Cable MP32 Software Startup Programming the CPM Remote Unit ID Destination TeleCom Mode Dialer Type Operating Mode Max BPS Answer Ring Count Firmware Version Primary Call Retry Rate Primary Call Retry Count Secondary Call Retry Interval Counter/Status Input Connect to on Input 1 Alarm Counter/Status Input Connect to on Input 2 Alarm Service Type PIN Number (GSM18 or GSM20 only) Frequency (GSM18 only) OTAA Programming Number (CDMA only) Programming the CPM Remote Unit ID Destination Originate Calls Respond to Voice Calls Respond to SMS Maintain Internet Connection Dual Port Firmware Version Primary Call Retry Rate Primary Call Retry Count viii

9 Secondary Call Retry Interval Counter/Status Input Counter/Status Input Serial Port-1 Settings Port Select ID Max BPS Data Bits Parity Type Stop Bits Serial Port-2 Settings Cellular Settings Service Type PIN Number (GSM only) Frequency (GSM18 only) GPRS Access Point Name (GSM only) Packet Service Connection Command OTAA Programming Number (CDMA only) PAP User Name and Password Programming the CNI METRETEK DATA COLLECTION SYSTEM Data Collection Modem Data Collection Modem Emulator Configuring the MODEM Channels Configuring for a MODSMOD Chassis Configuring for an InvisiConnect MODSMOD Emulator Configuration of the Data Collection Software Defining a New Device Defining Parameters for a CPM Configuring the Way Data is Collected and Stored Defining the Input Channels Defining the Call Schedule Defining the Alarm Inputs Defining Relay Schedules Synchronizing Relay Schedules for Multiple Units Defining Parameters for a CPM Configuring the Way Data is Collected and Stored Defining the Input Channels Defining the Call Schedule Defining the Alarm Inputs Configuring the InvisiConnect MODSMOD Emulator External IP Address IP Configuration and Control Start All and Stop All Start / Stop Deleting a Server Editing a Server Adding a Server User Application Interface IP Port Number Server Description Auto Start Server at Startup ix

10 5.5.8 COM Port Configuration SMS (Paging) Configuration Enable SMS / USSD Use SMTP Mail Server SMTP Server Address From Display Name From Address Use Attached Cellular Modem Cellular Modem Com Port Flow Control Baud Rate, Data Bits and Stop Bits Keep COM Port Open Use Send-Only Option Modem Reset and Initialization Strings Use Relay Server InvisiConnect Relay Server Relay Server Password SMS / USSD Prefix and Suffix Starting the Data Collection Software Viewing Data and Running Reports CNI OPERATION Call Retry Strategy Paging via Voice Call Paging via SMS Message What Causes the CNI to Call In? Alarm Condition Paging Scheduled Call Behavior when Originating a Call in CSD Mode Behavior when Answering a Call or Page in CSD Mode Behavior in Packet Mode Permanent ( Always On ) Internet Connection Transparent Mode (CSD Mode Only) Over-the-Air Activation (CDMA18 only) SAFETY, HAZARDOUS AREAS, ESD PRECAUTIONS TECHNICAL SPECIFICATIONS WARRANTY INFORMATION LIST OF TABLES CPM-1 Power Supply Configuration Jumpers Input Range Selection Jumpers MCM-II Jumper & Terminal Block Reference MCM-II Terminal Block Connections High Side / Low Side Shunt Selection Jumpers High Side Shunt Polarity Selection Low Side Shunt Polarity Selection Reference Cell Inputs Alternate Configuration Selection Jumpers x

11 External Antenna Kits Sample Delay for TTI Data in Relay Toggle Mode Special Transparent Mode Status Commands LIST OF FIGURES Cellular Data Collection System Concept using CSD Cellular Data Collection System Concept using the Internet Metretek Programmer Cable Enclosure Dimensions and Mounting Hole Locations View of the DC-Powered CPM View of the AC-Powered CPM View of Single-Channel CPM View of Dual-Channel CPM-1 without Inter-Channel Isolation View of Dual-Channel CPM-1 with Inter-Channel Isolation AC-Powered, Dual-Channel CPM-1 Internal Wiring Diagram DC-Powered, Dual-Channel CPM-1 Internal Wiring Diagram Single-Channel CPM-1 Internal Wiring Diagram ILI Board Layout Connection of an External Serial Device to the CPM Dual Port Multiplexer Board Directly Installed Multiplexer Board Typical Wiring of Two Serial Devices to the Multiplexer Board Internal View of the AC-Powered CPM CPM-2 Internal Wiring CNI Terminal Block MCM-II Board Simplified Cathodic Panel Component LCA110 (U17 on board) Component PM1204 (U5 on board) AC Power Supply Board AC Power Supply Board AC Mains Transformer DC Power Supply Board DC Power Supply Board Installation of the rechargeable battery Primary Components of the Model GSM18 CNI Board Primary Components of the Model GSM20 CNI Board Primary Components of the Model CDMA18 CNI Board Block Diagram of the CNI Board B-001 Single-Band Antenna Quad-band Antenna Optional External Antenna Kit SIM Card Profile GSM18 SIM Card Holder Location GSM20 SIM Card Installation Location of ESN number on the c18 radio MP32 Login Screen MP32 Start-Up Screen xi

12 Communication Port Configuration Screen Main Configuration Screen for CPM Cellular Settings Screen for CPM Main Configuration Screen for CPM Serial Port Configuration Screen for the CPM Cellular Settings Configuration Screen for the CPM Modem Configuration Screen Opening Screen for Remote Unit Manager Defining a New Remote Unit CPM-2 Data Configuration Screen CPM-2 Input Configuration Screen CPM-2 Call Schedule Configuration Screen CPM-2 Alarm Configuration Screen CPM-2 Relay Configuration Screen CPM-2 Preferences Screen CPM-1 Data Configuration Screen CPM-1 Input Configuration Screen CPM-1 Call Schedule Configuration Screen CPM-1 Alarm Configuration Screen InvisiConnect Main Screen InvisiConnect Add / Edit Interface Configuration Screen InvisiConnect Serial COM Port Configuration Screen SMS/USSD Settings Screen CNI s LED Indicators xii

13 1 PRODUCT DESCRIPTION The Cellular Network Interface is simply referred to as the CNI throughout this document. These units are configured as legacy Metretek data collection devices known as a Cathodic Protection Monitors, or CPMs. 1.1 Product Overview All metals and many liquids conduct electrical current. The generation and transmission of electrical current is essential for modern day living but in some instances it is unintentional and possibly disastrous. When metal structures or pipes come in contact with the earth an electrical path can be created. As current flows between the metal and the ground, corrosion can occur in the metal. After a period of time the integrity of the metal is compromised, leading to structural failure or holes in the pipes. For years the only solution to this problem was a regular schedule of on-site inspection and eventual repair or replacement of the damaged metal. This is a costly process, especially if there are many structures or miles of pipeline to inspect. More recently methods have been developed to measure the electrical activity at various points. In its simplest usage the information can possibly reduce the number of inspections or pinpoint problem areas that require the most attention. In more sophisticated systems equipment can be added to impose another current of equal magnitude and opposite direction, essentially eliminating the damage altogether. Metretek s Cellular Network Interface (CNI), acting as a Cathodic Protection Monitor (CPM), is another member of a reliable, time-proven family of data collection and control systems. The system consists of both hardware and software. The information gathered by the CNI must eventually be transferred to a computer system for processing. On the computer is a sophisticated data collection program that can process calls from hundreds of devices per hour, process and organize the data, and issue new instructions to the devices when needed. Many legacy Metretek data collection devices have built-in modems and telephone line interfaces that connect directly to any standard wired phone service. However, wired phone service may not exist in all areas, may be too expensive to install or may not be permitted in hazardous locations. The CNI was specifically designed to address these problems. Operating as a wireless modem, a connection is made using commercial digital cellular GSM or CDMA phone networks. The GSM18 supports 900 / 1800 / 1900 MHz GSM, used throughout most of the world. The GSM20 supports 850 / 1900 MHz or 900 / 1800 MHz GSM. The CDMA18 supports 850 & 1900 MHz CDMA service. Any model can make a circuit-switched data (CSD) or a packet service (Internet) connection to another computer providing that this service is offered by the cellular providers. Effective December, 2005 Metretek discontinued production of the GSM18. However it remains fully documented in this manual for existing owners. In North America many of the original analog cellular networks started operation on the 850 MHz band. Later the 1900 MHz band was allocated for newer digital services. As analog service is being phased out the 850 MHz networks are being converted to digital GSM service. The 1-1

14 GSM18 did not support the 850 MHz band but the newer GSM20 does. Older GSM18 units can be easily converted to 850 and 1900 MHz operation by purchasing a small adapter board. Contact Metretek for more information. The CPM-1 can measure one or two analog signals as high as 150 Vdc with complete isolation. It can also be connected to any external serial (RS-232) device and will allow the central computer to directly communicate with that device. The RS-232 port is not isolated. The CPM-2 allows up to eight analog signals to be measured, alarm situations to be monitored and external equipment to be controlled in an orderly and precise fashion. A single Form-A input can be configured to count pulse data from an external device or monitor an alarm switch. An additional Form-A input is available as an alarm input only. The analog and digital inputs are not isolated. Unlike the CPM-1 this unit does not provide access to a serial port. AC-powered units operate from 12 VAC using a step-down, wall-mount transformer. They also have an internal rechargeable battery that provides backup power should the primary power source fail. DC-powered units contain a rechargeable battery and an inexpensive off-the-shelf alkaline battery used as the charging source. Both models monitor and report tampering (door open) and loss of AC power or low-battery conditions. 1.2 Wireless Data Collection Concept Remote data collection is essentially comprised of three basic components: 1. A device to measure and digitize the voltages and currents. 2. Data collection circuits with a microprocessor and memory to record these measurements and alarm events. 3. A communications path to permit the transfer of the information to a central computer for processing. This communications path could include local area networks, wireless data links, or the more conventional method of using a modem and wired telephone line. Selecting a communications network to reliably transfer the collected data poses a great challenge. Economic factors come into play where the initial product cost must be weighed against monthly network service charges. This is further complicated when considering the rapid pace with which communications systems are evolving. Some points to consider when selecting a network are: - Satellite or microwave data links have a high initial cost and a high ongoing cost to maintain the service. Advantages include high reliability and high bandwidth (fast data transfers). - Wired telephone line connections with a modem circuit were the most common solutions for cost-sensitive applications. Installation and operation costs depend upon 1-2

15 how accessible a phone line is at the site, whether the line is dedicated or shared, and whether the calls are local or long distance. Monthly service charges continue to increase and the cost of running lines into new areas has increased dramatically. - Analog cellular phone service has been used in areas where phone lines do not exist. While the initial purchase price of the service can be higher than that of a wired line system, it eliminates the expense of running telephone wires over long distances. In some hazardous sites, telephone lines are not permitted. However, the limited capacity of analog cellular technology has led to the development of digital methods to increase capacity and provide new features. Analog service is quickly being phased out in many parts of the world. - Digital cellular networks are rapidly expanding and replacing earlier analog systems. More efficient use of the radio spectrum permits the network to handle many more calls at a given time, and to offer new features including data exchange. In the case of the CNI, a GSM or CDMA cellular phone link is utilized to provide the most economical and reliable solution. Figure 1-1 illustrates a typical remote data collection system using a cellular network in CSD mode. Communications are wireless between the CNI and base station tower, while conventional wired telephone service is used for the connection between the cellular base station and the modem at the central computer site. Data communication speeds will usually be either 4800 or 9600 bps on GSM networks, or most conventional baud rates up to 9600 on CDMA networks. Figure 1-1 Cellular Data Collection System Concept using CSD 1-3

16 Figure 1-2 illustrates a similar system using the cellular network s packet (Internet) service. The CPM knows the Internet address of the computer running the data collection software (the server ), and data is exchanged in packets using standard Internet protocol. Figure 1-2 Cellular Data Collection System Concept using the Internet 1.3 Communications Scenarios NOTE: For circuit-switched data (CSD) calls the central computer must be connected to a Metretek MODSMOD modem. This device supports up to 8 phone line connections. It also supports a proprietary and secure communications format that rejects incoming calls from non-metretek devices. CSD is supported by either the CPM-1 or CPM-2. For Packet (Internet) connections an additional program called InvisiConnect Server is installed which serves as a secure bridge between the Internet and the CPM data collection software. InvisiConnect emulates a MODSMOD modem. At the present time only the CPM-1 supports packet mode. Scenario #1: The CNI initiates a CSD call to the central computer running Metretek s CPM data collection software. The CNI determines that a call should be made due to an alarm condition or a regularly scheduled call event. 1-4

17 The CNI s cellular radio establishes a connection with the cellular phone network and initiates an outbound CSD data call to the central computer. The central computer answers the call, processes the CNI s data, stores it in a database structure format and issues new instructions to the CNI. Scenario #2: The data collection computer, which is running Metretek s CPM data collection software, initiates a CSD data call to the CNI (this is known as a mobileterminate connection and may not be supported by all service providers). The CNI s cellular radio is registered with the cellular network, and is therefore always listening for an incoming call. This mode is only recommended for ACpowered units because the radio must remain powered up at all times. The central computer dials the radio s data number (this is known as a mobileterminate CSD connection). When the CNI answers the call it will establish a link with the computer s modem. The computer processes the CNI s data, stores it in a database structure format and issues new instructions to the CNI. Scenario #3: The CNI establishes an Internet connection to the central computer, which is running both the CPM data collection software and Metretek s InvisiConnect Server software. The CNI determines that a call should be made due to an alarm condition or a regularly scheduled call event. The CNI s cellular radio uses the cellular network s packet service to establish an Internet connection with the central computer. InvisiConnect Server software verifies that the remote device is a Metretek device. It then acts as a transparent bridge between the CNI and the CPM data collection software. The CPM software processes the CNI s data, stores it in a database structure format and issues new instructions to the CNI. Scenario #4: The data collection computer pages the CNI and waits for the CNI to call back. Some cellular service providers may not support mobile-terminate CSD connections (the CNI can place calls but cannot be called). For Internet connections it is not possible to contact the CNI via the Internet because it only acts as a client and is not listening for connection requests. Only a server does that. In these cases the CNI can be paged, which will cause it to immediately call back. The CNI cellular radio is registered with the cellular network, and is therefore always listening for a page. This mode is only recommended for AC-powered units because the radio must remain powered up at all times. 1-5

18 If the cellular account has been assigned a voice or data phone number, the computer calls that number. The CNI answers the call and attempts to communicate with a modem (which isn t present). After several seconds the CNI hangs up and will immediately call back as described in Scenario #1 or #3. If the cellular account includes a feature called SMS (short message service), the computer can send a text message to the CNI using an SMTP ( ) server or with another wireless modem. When the CNI receives the message it will immediately call back as described in Scenario #1 or # Packet versus Circuit Switched Data (CSD) Service The CPM-1 and CPM-2 can communicate with the central computer s modem using a circuit-switched data (CSD) connection. Or the CPM-1 can exchange information with the central computer over the Internet. There are advantages and limitations to each method. Metretek s CPM data collection software supports CSD connections. For Internet connections Metretek s InvisiConnect Server software is used to provide a secure bridge between the Internet and the CPM data collection software. CSD mode is similar to two modems communicating over a wired telephone line. The cellular service provider has banks of modems available in their switching centers. When it detects a CSD call it connects one of its own modems to the wired line. Data is transferred between the CNI and the switching center over the radio link, and then between the switching center and the destination modem via wire. Cellular service providers often offer this service as an add-on package to a standard voice account, and each call is measured and billed in terms of minutes used. Depending upon the frequency and length of the calls this service can become quite expensive. In situations in which the calls are long distance it may be possible to purchase plans that include free long distance in order to reduce costs. Some service providers in North America no longer support CSD service. Those that do may not support mobile-terminate connections, in which case the CNI can place a call but cannot be called. GSM cellular service providers may offer access to the Internet using a service called GPRS (general packet radio service). CDMA cellular service providers may offer access to the Internet using a service called 1X or 1XRTT (single carrier, radio transmission technology). Data is exchanged in small blocks, or packets, with a computer running Metretek s InvisiConnect Server software. Cellular service providers may offer this service as an add-on package to a standard voice account, or may offer it as a standalone product. Each connection is usually measured and billed in terms of the amount of data exchanged, usually in increments of 1 million bytes (1 Mb) per month. The amount of information exchanged on each call may range from several hundred bytes to 10 s of thousands of bytes, depending upon the information that is requested from the CNI. It may be necessary to test the system for several months and then adjust the cellular account for the best cost based on your needs. 1-6

19 2 INSTALLATION AND TECHNICAL INFORMATION 2.1 Unpacking, Damage Reports, Item List Unpacking / Damage reports Upon receipt, inspect the equipment for any potential shipping damage. There should be no loose components within the enclosure or any impact marks on the walls or outside edges of the fiberglass housing. Heavy items (batteries, power transformers, etc.) are shipped separately rather than inside the enclosure to prevent internal damage from shifting contents. If any damage is detected that can be attributed to the way the package was handled, then a claim should be filed with the shipping agent as quickly as possible. Shipping Contents All versions of the CPM-1 and CPM-2 are provided with the following items: The Cellular Network Interface (CNI) board. A cellular radio mounted directly to the CNI board. Antenna (mounted directly to the radio or externally mounted to the side of the enclosure and connected to the radio). Nema 4X enclosure. 12-volt, 2.5 A-hr sealed lead-acid battery. Manual (this document). Normally only one manual is included with each shipment rather than with each unit. Additional manuals can be ordered separately or obtained in PDF file format upon request. A typical AC-Powered CPM-1 also contains: CPM-1 firmware option. One or two Isolated Linear Integrator ( ILI ) boards. One or two 3.6-volt, lithium D -sized batteries AC power supply board. Wall-mount transformer, 120 VAC in, 12 VAC out. A typical DC-Powered CPM-1 also contains: CPM-1 firmware option. One or two Isolated Linear Integrator ( ILI ) boards. One or two 3.6-volt, lithium D -sized batteries DC power supply board. 6V, 40 A-hr alkaline lantern battery 2-1

20 A typical AC-Powered CPM-2 also contains: CPM-2 firmware option. A Measurement and Control Module ( MCM ) board. AC power supply board. Wall-mount transformer, 120 VAC in, 12 VAC out. Note: The items listed above may vary depending on what was requested with the original purchase order. Refer to the shipping document or the purchase order for a precise record when inspecting the package contents. 2.2 Additional Items Required for Installation Several additional tools and items will be required before proceeding with the field site installation. These are: Equipment available from Metretek: Metretek programmer cable as illustrated in Figure 2-1. This item can be obtained under stock number B-001. MP-32 programmer software, available under stock number Additional items required for installation: Figure 2-1 Metretek Programmer Cable Computer system for configuration, with a Windows-98 or higher operating system. A laptop machine is typically recommended if the CNI is to be programmed in the field. GSM service requires a small memory card known as a SIM card. This must be obtained from the cellular service provider. Refer to Chapter-3 for additional details regarding SIM card activation. CDMA units do not require a SIM card but do require a cellular account to be activated. Voltmeter for troubleshooting. 2-2

21 Hand tools, fasteners, mounting hardware, PVC pipe, etc. For AC-Powered units a 2-conductor 18AWG cable with weather resistant PVC jacket for making the wiring connection between the power supply transformer and the power supply board within the enclosure. 2.3 Enclosure Dimensions and Site Selection It is highly recommended that the CNI be configured and tested prior to being installed at the field site. Metretek verifies operation of each unit using service providers and frequencies that are available in the area where the CNI is manufactured. It is best to verify operation using your service provider and in the approximate area where the unit will be installed. All versions of the CPM-1 and CPM-2 use the same NEMA4X enclosure. Mounting of the CNI is normally accomplished by bolting the enclosure to a wall or other support structure. The four mounting holes are capable of accepting bolts of 5/16 (7.9 mm) maximum diameter, although smaller bolts can be used with washers. See Figure 2-2 for dimensional information and hole spacing. WARNING No hazardous area safety approvals have been received for this product. It is therefore necessary to ensure that the product is only installed at locations that are classified as safe area sites. See Chapter-7 for more safety information. 2-3

22 Figure 2-2 Enclosure Dimensions and Mounting Hole Locations Field site selection for a cellular communications product requires consideration with regard to antenna placement. For units with external antennas ensure that the antenna is pointing in a vertical direction. Mount the unit away from buildings and structures when possible. Buildings tend to block the signal if they lie in the path between the cellular tower and the CNI. Outdoor installations are preferred. Raise the elevation as high as practical from the ground. Avoid mounting the unit to the side of a metal shed or similar structure since metal is a very effective shield against the desired rf signal. Chain link fences are normally not a problem. Avoid mounting the product in a location where the antenna is in close proximity to a measurement instrument such as a Rosemont transducer. The strong rf field from the cellular module transmitter could possibly degrade the accuracy of these precision instruments. Conversely, nearby electronic equipment may interfere with the operation of the cellular radio. Depending on the signal strength for a given location, it may be possible to ignore some of these suggestions and still obtain good performance. This will vary from one site to the next, just as the reception quality of a handheld cellular phone will vary. 2-4

23 The CNI may have been ordered with a built-in antenna. If this antenna does not provide adequate performance a different antenna can be used as long as it complies with the impedance and frequency range of the cellular radio module. For instance, the CNI may be located in a metal building but a mobile antenna, such as the type that would mount to the roof of a vehicle, may be located outside of the building. Different antenna options are discussed later in this chapter. WARNING This product contains a radio-frequency transmitter, Motorola Model g18, FCC ID # IHDT6AC1, Motorola Model g20, FCC ID # IHDT56DB1 or Motorola Model c18, FCC ID # IHDT56CW1. The combined cable loss and antenna gain must not exceed 6.1dBi gain, and the antenna installation must provide a minimum separation distance of 20cm (8 ) from users and nearby persons and must not be collocated or operating in conjunction with any other antenna or transmitter. See Chapter-7 for more safety information. 2-5

24 2.4 Technical Information about the CPM CPM-1 Power Options Figures 2-3 shows the right-hand side of the DC-powered CPM-1 enclosure. The unit may be equipped with one or two lithium batteries depending upon the configuration. Figure 2-3 View of the DC-Powered CPM-1 2-6

25 Figures 2-4 shows the right-hand side of the AC-powered CPM-1 enclosure. The wallmount power adapter for the AC-powered unit is not shown. The unit may be equipped with one or two lithium batteries depending upon the configuration. Figure 2-4 View of the AC-Powered CPM-1 2-7

26 2.4.2 Layout of a Single-Channel CPM-1 A single-channel CPM consists of one Isolated Linear Integrator ( ILI ) board, one 3.6V lithium D cell and the CNI board. Radio and antenna arrangements will vary with model. Figure 2-5 View of Single-Channel CPM-1 2-8

27 2.4.3 Layout of a Dual-Channel CPM-1 without Inter-Channel Isolation A dual-channel CPM without inter-channel isolation consists of two Isolated Linear Integrator ( ILI ) boards, one 3.6V lithium D cell and the CNI board. Radio and antenna arrangements will vary with model. The lithium battery powers both ILI boards. This configuration provides isolation between the analog signals and the digital electronics, but not between the two ILI boards themselves. Figure 2-6 View of Dual-Channel CPM-1 without Inter-Channel Isolation 2-9

28 2.4.4 Layout of a Dual-Channel CPM-1 with Inter-Channel Isolation A dual-channel CPM with inter-channel isolation consists of two Isolated Linear Integrator ( ILI ) boards, two 3.6V lithium D cells and the CNI board. Radio and antenna arrangements will vary with model. Each lithium battery powers a separate ILI board. This configuration provides isolation between the analog signals and the digital electronics and between the ILI boards themselves. Figure 2-7 View of Dual-Channel CPM-1 with Inter-Channel Isolation 2-10

29 2.4.5 Internal Wiring of a Dual-Channel, AC-Powered CPM-1 The basic wiring between the components of a dual-channel AC-Powered CPM-1 is shown in Figure 2-8. This diagram is for units without inter-channel isolation. For units with inter-channel isolation there would be another lithium battery connected to ILI circuit board B and the W1 / W2 connections between the two boards would be removed. Figure 2-8 AC-Powered, Dual-Channel CPM-1 Internal Wiring Diagram 2-11

30 2.4.6 Internal Wiring of a Dual-Channel, DC-Powered CPM-1 The basic wiring between the components of a dual-channel DC-Powered CPM-1 is shown in Figure 2-9. This diagram is for units with inter-channel isolation. For units without inter-channel isolation the lithium battery connected to ILI circuit board B would not be present and the power lines of both ILI boards would be connected together. Figure 2-9 DC-Powered, Dual-Channel CPM-1 Internal Wiring Diagram 2-12

31 2.4.7 Internal Wiring of a Single-Channel CPM-1 The basic wiring between the components of a single-channel DC-Powered CPM-1 is shown in Figure The same basic configuration applies to AC-powered units. See Figure 2-8 for details about the ac power supply. Figure 2-10 Single-Channel CPM-1 Internal Wiring Diagram 2-13

32 2.4.8 ILI Board Layout The ILI board is a calibrated device. Do not readjust or replace any components! The CPM-1 consists of one or two Isolated Linear Integrator ( ILI ) circuit boards, one for each analog signal to be measured. One of these boards is shown in Figure For units without inter-channel isolation the two boards are physically connected to each other and electrically share the same power supply from a lithium battery pack. For units with inter-channel isolation the two boards are physically connected to each other but do not share the same power supply. Figure 2-11 ILI Board Layout 2-14

33 2.4.9 Power Requirements The ILI boards require an independent power source in order to maintain complete isolation between the signals being measured and the CNI electronics. The ILI will accept power supply voltages between 2.5 Vdc and 12 Vdc. Several jumpers must be set to the proper positions as shown in the following table: Power Supply JP1 JP4 Voltage Range Vdc IN OUT Vdc OUT IN Table 2-1 CPM-1 Power Supply Configuration Jumpers NOTE The standard CPM-1 is supplied with a 3.6 Vdc lithium battery. The JP1 and JP4 jumpers are configured at the factory for this battery Analog Signal Voltage Range To measure the analog signal with the best accuracy and resolution, choose the closest but next highest range shown in the next table: For instance, if the signal will reach 6 V, then choose the 12 V range. Full Scale Input Voltage JP2 JP3 0 to V A A-B 0 to +3 V A B-C 0 to +5 V B B-C 0 to +12 V C B-C 0 to +24 V D B-C 0 to +50 V E B-C 0 to +75 V F B-C 0 to +100 V G B-C 0 to +150 V H B-C Table 2-2 Input Range Selection Jumpers 2-15

34 How the ILI Board Works With jumper JP1 out and JP4 in power supply voltages between 6.1 and 12 Vdc are simply regulated down to +5 Vdc. With jumper JP1 in and JP4 out voltages between 2.5 and 6 Vdc are first doubled by a switched-capacitor boost regulator, then regulated down to +5V. A switched-capacitor inverter generates 5V from the +5V supply to power the analog circuitry. An additional circuit generates a stable 2.7 Vdc reference voltage that is used in several places. When the power supply drops to a value of about 2.7V, an optically coupled switch will turn on for approximately 60 milliseconds. The output of this switch is connected to an alarm input on the CNI board. When the CNI senses this event it will call in to report the condition. The battery should be replaced as soon as possible. The analog signal to be measured is connected to terminal block TB1, Positions 1 (+) and 2 (-). Depending upon the setting of jumpers JP2 and JP3, the signal will either be amplified or reduced with a certain degree of precision. This signal then controls a precision timing circuit that generates a linear pulse stream of 0 to 5 pulses-per-second. This corresponds to an analog input range of 0V to full scale. To minimize current drain the pulses are kept as short as possible, approximately 400 microseconds each. The pulse train is used to drive several optically coupled switches. The outputs of the two ILI boards are connected to the two data inputs on the CNI board. The CNI is configured to count these pulses over a certain time interval and save the totals as records in memory. A large interval will allow records to be stored over a longer period of time. A short interval will allow trends to be observed with better resolution. The data collection software can convert these time-tagged interval (TTI) readings back into voltage readings using a simple formula. As an example assume that the ILI has been configured for a full-scale range of 75V. The ILI board will produce 0 pulses for 0V and up to 5 pulses per second at 75V. Suppose over a 15-minute (900 second) period the final count is (final count) x (full scale range) Voltage = (Interval in seconds) x (pulses per second at full scale) (2760) x (75V) Voltage = (900 seconds) x (5 pulses per second) Voltage = 46V Chapters-4 and 5 have more information about configuring the CNI and the data collection software. 2-16

35 Wiring External Devices to the CNI s Communications Port For the CPM-1 an external serial (non-isolated RS-232) device can be connected to the CNI s serial port. If the CNI cannot establish communications with a Metretek modem within a certain period of time, a special transparent mode will be entered. This allows for direct communications between the external device and the central computer. This mode is only supported in CSD mode and not packet (Internet) mode. A minimum of three lines is required: a line to transmit data to the CNI, one to receive data from the CNI, and common. The CNI does not support hardware handshaking. The CNI must be properly configured to support this mode. See Chapter-4. The communications parameters are programmable. The bit rate programmed for the port must match that of the external device and of the central computer s modem. For GSM products this is generally 9600 bps. For CDMA units this is usually any common rate up to Figure 2-12 Connection of an External Serial Device to the CPM

36 Optional RS-232 Dual-Port Multiplexer The optional dual-port multiplexer board (Metretek Stock # ) allows two RS-232 devices to connect to one CNI. You can program different communication parameters for each port, such as bit rate, parity, etc. Figure 2-13 Dual Port Multiplexer Board 2-18

37 Direct Connection of the Multiplexer Board Figure 2-14 depicts the multiplexer board installed directly to the CNI. The pins of the multiplexer board are inserted into the CNI s terminal block. All screws on the CNI s terminal block must be tightened to ensure proper electrical contact. Connections are then made to the multiplexer board s terminal block for all alarm inputs as well as the serial communications connections to the two serial devices. Figure 2-14 Directly Installed Multiplexer Board 2-19

38 Figure 2-15 depicts a typical wiring diagram for two serial devices. Figure 2-15 Typical Wiring of Two Serial Devices to the Multiplexer Board The CNI must be informed that the dual-port multiplexer is installed. See Chapter-4 about this. The multiplexer can also be controlled remotely using the InvisiConnect software, discussed in Chapter

39 2.5 Technical Information about the CPM Internal Components of the AC-Powered CPM-2 A view of the AC-Powered CPM-2 is shown below. Radio and antenna arrangements will vary with model. The external wall-mount transformer is not shown. Figure 2-16 Internal View of the AC-Powered CPM

40 2.5.2 Internal Wiring of the CPM-2 The basic wiring between the components of the CPM-2 is shown below. Figure 2-17 CPM-2 Internal Wiring Wiring to the Pulse / Alarm Inputs Figure 2-18 illustrates the connections that can be made to the CNI terminal block. The tamper input has been wired at the factory to report if the enclosure door has been opened. Normal service visits will therefore be registered as well as any unauthorized access. If needed this magnetic switch can be disconnected and the input can be used for another purpose. For such applications, the external switch type should be a Form-B (normally closed). When using the tamper input with an external switch, it should be remembered that a transition from the normally closed state to an open circuit is the event that will trigger a call. 2-22

41 Figure 2-18 CNI Terminal Block Inputs 1 and 2 are available for wiring to simple Form-A (normally open) contact closures as illustrated in Figure Input-1 can be either a data (pulse) or alarm input, while Input-2 can only serve as an alarm input. The 2-pin connector labeled J2 is used to manually trigger a call by momentarily shorting the pins with the end of a screwdriver or similar metallic object. It is wired in parallel with positions 1 & 2 of the terminal block. It is also possible to wire a pushbutton switch or another alarm input to J2 or to positions 1 & 2 of the terminal block if desired. An external switch or alarm input must provide a contact closure lasting a minimum of 1 second to ensure that the call is triggered. The switch should be of a Form-A type (normally open). Route all wires through the plastic wire inlets at the bottom of the enclosure. Then tighten the nut on the plastic connector until the internal rubber sleeve shrinks around the wires. This will provide a strain relief, as well as preventing insects from gaining access to the inside of the enclosure. WARNING Never apply a power source to terminal block positions 1 thru 7. This could result in damage to circuit components and cause personal injury. 2-23

42 2.5.4 RS-232 Serial Data Port The RS-232 port on the CNI terminal block is pre-wired to the MCM board s serial port. This permits the CNI to download data samples from the MCM board on a regular basis. Commands are sent by the CNI to the MCM for controlling the analog input channels and setting the relay outputs. This serial port connection is comprised of four wires as follows: TXD (transmit data) RXD (receive data) DSR (data set ready) GND or Common TXD and RXD perform the data exchange between the two boards using a bit rate of 9600 bps, 8 data bits, 1 stop bit, and no parity. DSR is used to wake the MCM from its sleep mode and prepare it for the receipt of commands MCM-II Board Layout The MCM board is a calibrated device. Do not readjust or replace any components! Figure 2-19 illustrates the MCM-II circuit board, terminal block numbering, and jumper information. The six terminal blocks can accept wires between 24 and 18 gauge. A small flat-blade screwdriver is required for compressing or releasing the clamping jaws of the terminal blocks. Numerous jumpers also exist on the board for the purpose of selecting different configuration options. This will be discussed shortly. 2-24

43 Figure 2-19 MCM-II Board Circuit Board Jumpers Several different jumper types are used on the MCM-II board: JP23 and JP24 are two position headers that simply have a shorting jumper either completely installed or removed. JP9 thru JP19 are three position headers that always have a shorting jumper installed. This jumper is either placed across position A+B or else position B+C. JP1, JP2 and JP3 are four position headers that always have a single shorting jumper installed. This jumper is placed across either the two positions marked A- A, or else the two positions marked B-B. Table 2-3 provides information regarding the appropriate jumper settings for the various options and voltage ranges. 2-25

44 Table 2-3 MCM-II Jumper & Terminal Block Reference 2-26

45 2.5.7 Terminal Block Circuit Connections Six terminal blocks on the MCM-II board are utilized for making all necessary connections to the external cathodic protection system, as well as the CNI circuit board. Terminal block TB4 has been pre-wired at the factory to the CNI board. Table 2-4 provides a sequential listing of the terminal block connection points. Position Label Function TB1-1 Pipe-1 Pipe-Soil Input #1 TB1-2 Ref-Cell-1 Reference Cell #1 Connection TB1-3 Pipe-2 Pipe-Soil Input #2 TB1-4 Ref-Cell-2 Reference Cell #2 Connection TB1-5 Pipe-3 Pipe-Soil Input #3 TB1-6 Ref-Cell-3 Reference Cell #3 Connection TB2-1 (-) Rect. Rectifier (-) Voltage Input TB2-2 LSS1 Low Side Shunt Input #1 TB2-3 LSS2 Low Side Shunt Input #2 TB2-4 LSS3 Low Side Shunt Input # TB3-1 HSS1 High Side Shunt Input #1 TB3-2 HSS2 High Side Shunt Input #2 TB3-3 HSS3 High Side Shunt Input #3 TB3-4 (+) Rect. Rectifier (+) Voltage Input TB4-1 TXD Serial Data Port TXD Line, RS-232 Levels TB4-2 RXD Serial Data Port RXD Line, RS-232 Levels TB4-3 Wake-Up Input to wake the MCM-II from the low power sleep mode. TB4-4 GND Circuit common for serial data port TB5-1 RLY1-A Function depends on JP23, reference Table 5-1. TB5-2 RLY1-Com. Function depends on JP23, reference Table 5-1. TB5-3 RLY1-B Function depends on JP23, reference Table 5-1. TB5-4 RLY2-A AC load connection point. Min. load = 5mA, max = 500mA. TB5-5 RLY2-Com. AC load connection point. Min. load = 5mA, max = 500mA. TB5-6 RLY2-B No connection TB V-In +12V input that powers the MCM-II board. TB7-2 GND Circuit common for the +12V input. TB V-Out Regulated +5.0V output. TB7-4 GND Circuit common for the +5.0V output. TB7-5 AC-Off Alarm output, provides indication of a power failure. TB7-6 GND Circuit common for the AC-Off alarm. Table 2-4 MCM-II Terminal Block Connections 2-27

46 2.5.8 Cathodic Rectifier Wiring to MCM-II Before a CNI system can be properly wired to a Cathodic Protection Rectifier, certain information concerning the wiring configuration of the rectifier itself must be determined. Figure 2-20 illustrates a simplified panel layout of a rectifier system with these components: A large terminal usually marked with + Anode or + Positive. This terminal normally has a large, heavy gauge wire which routes to the sacrificial anode bed. A large terminal usually marked with - Structure or - Negative. This terminal normally has a large, heavy gauge wire which routes to the structure being protected. A device known as a Shunt Resistor. This component looks like a large metal strap. It is normally wired in series with the rectifier s anode connection or structure connection. When current passes through the shunt a small voltage (usually less than 100 millivolts) is developed across its terminals that is proportional to the current. Figure 2-20 Simplified Cathodic Panel 2-28

47 Determining the Rectifier s Configuration The four terminals just described, anode, structure, and either side of the shunt resistor must be measured with the rectifier powered on to determine how the MCM-II board should be attached and jumpered. 1. Using a voltmeter set to an appropriate range, measure the voltage across the rectifier s Anode (+) terminal and the Structure (-) terminal. Record this measurement. 2. Leaving the minus lead of the voltmeter on the Structure (-) terminal, move the positive lead of the voltmeter to either terminal of the shunt resistor. One of the following should be observed: A voltage very close (within 100 millivolts) to the reading taken in step #1. This indicates the shunt is wired in series with the rectifiers Anode (+) terminal. This will henceforth be referred to as a High Side Shunt. A voltage very close (within 100 millivolts) to zero. This indicates that the shunt is wired in series with the rectifier s Structure (-) terminal. This will henceforth be referred to as a Low Side Shunt. 3. Using the voltmeter set to a low scale (less than a volt), measure across the terminal of the shunt resistor itself. This reading should be under 100 millivolts. Note which shunt terminal is positive and which is negative when making this reading Configuring the MCM-II Jumpers Before making the attachment of the inputs to be monitored, the jumper settings on the MCM-II circuit board should be verified. If the maximum rectifier output voltage does not exceed 75 volts DC, the jumpers for Channel-1, JP-9, should be placed in the A-B position; otherwise JP-9 should be installed in the B-C position (accepts a maximum rectifier voltage of 200Vdc). The input range for the current Channels 2, 3, and 4 is 0-100mV. These channels are designed to attach to shunt resistors on either the high or the low side of the rectifier as determined in Step 2 above. Connect the jumpers as follows: Channel Number High Side Shunt Low Side Shunt 2 JP-12, JP-15, JP-17 = A+B JP-12, JP-15, JP-17 = B+C 3 JP-11, JP-14, JP-18 = A+B JP-11, JP-14, JP-18 = B+C 4 JP-10, JP-13, JP-19 = A+B JP-10, JP-13, JP-19 = B+C Table 2-5 High Side / Low Side Shunt Selection Jumpers 2-29

48 Channels 5, 6, and 7 are intended for use as pipe-to-soil inputs. These channels are designed with high input impedance and are the most suitable inputs on the MCM-II board for taking pipe-to-soil measurements. These inputs are bipolar (can yield positive or negative readings) with a standard range of -3 to +3 volts. This range is selected by removing jumpers from JP-3, JP-2, & JP-1 for channels 5, 6, & 7 respectively. Optionally, a range of -50 to +50 volts can be selected by installing these jumpers. Additionally, if Channel-7 is to be used for either range, JP-16 should be placed in the B+C position Rectifier Connections to the MCM-II Board If the shunt resistor on the rectifier was determined to be a High Side Shunt, make the following connections to the MCM-II board: Cathodic Connection Point MCM-II Description Positive terminal of shunt TB3-4 CH-1: Rectifier voltage (+) input resistor Negative terminal of shunt TB3-1 CH-2: High side shunt 1 input resistor Structure (-) terminal of rectifier TB2-1 Circuit common for CH-1 & CH-2 inputs Table 2-6 High Side Shunt Polarity Selection If the shunt resistor on the rectifier was determined to be a Low Side Shunt, make the following connections to the MCM-II board: Cathodic Connection Point MCM-II Description Anode (+) terminal of rectifier TB3-4 CH-1: Rectifier voltage (+) input Positive terminal of shunt TB2-2 CH-2: Low side shunt 1 input resistor Negative terminal of shunt resistor TB2-1 Circuit common for CH-1 & CH-2 inputs Table 2-7 Low Side Shunt Polarity Selection If the rectifier is equipped with multiple shunts (either high or low side), repeat steps 2 & 3 to determine if they are wired on the rectifier s high side or low side, which shunt terminal is positive, and which is negative. If the additional shunt is high side, attach a wire from the shunt s negative terminal to TB3-2 (for input 3) or TB3-3 (for input 4). If the additional shunt is low side, attach a wire from the shunt s positive terminal to TB2-3 (for input 3) or TB2-4 (for input 4). Note: The MCM-II board can measure a total of three shunt resistors whether they are wired to either the rectifier s high or low side. Do not attach inputs to both the high and low side terminals for a single given input (for example, TB3-1 and TB2-2 on input 2) as 2-30

49 the unit can only monitor one of these two terminals as determined by the MCM-II s jumper settings Reference Cell Connections Three reference cell inputs are available for making structure-to-soil measurements. Attach these inputs as follows: Cathodic Connection Point MCM-II Description Reference Cell - 1 TB1-1 Pipe-Soil: Input 5 (+) Pipe - 1 TB1-2 Pipe-Soil: Input 5 (-) Reference Cell - 2 TB1-3 Pipe-Soil: Input 6 (+) Pipe - 2 TB1-4 Pipe-Soil: Input 6 (-) Reference Cell - 3 TB1-5 Pipe-Soil: Input 7 (+) Pipe - 3 TB1-6 Pipe-Soil: Input 7 (-) Table 2-8 Reference Cell Inputs Special Connection Options These special configuration options are available but not normally required or used with most CPM installations. Optionally, channels 2, 3, & 4 can be used as general-purpose - 2 to +2 volt inputs (referenced to the negative side of the rectifier). To make this selection, configure the jumpers as shown below: Channel Number Jumper Configuration 2 JP-12 = B+C, JP-15 = B+C, JP-17 = A+B 3 JP-11 = B+C, JP-14 = B+C, JP-18 = A+B 4 JP-10 = B+C, JP-13 = B+C, JP-19 = A+B Table 2-9 Alternate Configuration Selection Jumpers Channel - 7 can instead be used to monitor the temperature at the site. To do this, simply place JP-16 in the A+B position. This will produce a voltage level that tracks temperature at a rate of approximately 10mV per degree Centigrade Relay Outputs Rectifier control relays are designed to provide remote control of rectifier power and onoff switching of rectifier power synchronized with other CNI remote units. The opto-relays supplied with the CPM-2 can be used to control the operation of a larger solid state AC or solid state DC relay. These larger relays are designed to handle the high voltage and/or high current often encountered in rectifier loads. A schematic illustration of Relay #1 is shown in Figure 2-21 and a similar sketch of Relay #2 is provided in Figure

50 Opto-Relay #1 This relay can be configured to support either AC or DC type loads depending on the setting of jumper JP-23. (IN = DC mode, OUT = AC mode) This relay has a part number of LCA110, and is manufactured by Clare Inc. Detailed electrical specifications for this component can be obtained at Opto-Relay #2 This relay is intended to support AC type loads that have a burden within the range of 5mA (minimum) to 500mA (maximum). Jumper JP-24 must never have a shorting jumper installed (reference Table 2-3) since this relay does not operate with DC loads. This component has a part number of PM1204, and is manufactured by Clare Inc. Detailed electrical specifications for this part can be obtained at Figure 2-21 Optical Relay Schematic Component LCA110 (U17 on board) Figure 2-22 Optical Relay Schematic Component PM1204 (U5 on board) 2-32

51 When using Metretek s Power Interruption Modules, U17 must be removed from it s socket since it will not be used. After doing so, use one small piece of wire to short empty socket pins 1 to 6 and another to short socket pins 2 and 5. Then wire as described in Power Interruptor Manual #

52 2.6 Component Common to Both the CPM-1 and CPM AC Power Supply Board Figure AC Power Supply Board Figure AC Power Supply Board There is one of two power supply boards used depending upon the age of the unit. The primary input source for the power supply board is 12 VAC at Hz, typically provided by a 120 VAC-to-12 VAC wall-mount power transformer. The output of the transformer connects to the TB-1 terminal bock. A 2.5 amp pico fuse at location F1 protects this input. The power supply board provides four functions. First, the board provides a regulated, low current (100mA) +4.2V supply for the CNI board. It is the primary power source when the radio is not being used and maintains the processor circuits and memory. 2-34

53 This supply appears on the J3 connector of the power supply board (J3-1 is positive and J3-2 is ground). It connects to the J3 connector on the CNI board (J3-4 is positive and J3-1 is ground). When the radio is powered up the CNI generates a logic high signal on its J6 connector that causes the power supply board to turn on a high-current supply (J6-3 is signal and J6-2 is ground). This logic signal is connected to the J3 connector on the power supply board (J3-5 is signal and J3-6 is ground). The 12V high-current output appears on the J2 connector of the power supply board (J2-1 & 4 are positive and J2-2 & 3 are ground). The supply is connected to the TB2 terminal block on the CNI board (Pin-1 is positive and Pin-2 is ground). This supply provides the high current demanded by the radio. This supply voltage is regulated down to +5V on the CNI board. The third function is to supply a constant 12.6V charging voltage for the lead acid battery, which is connected to the J1 connector (J1-2 is positive and J1-1 is ground). A 2.5 amp pico fuse at location F3 protects this input. Nominal charging voltage is 13.5V. Finally the board monitors the condition of the 12 VAC power and reports a power-fail alarm condition to the CNI when it fails. This is a logic low signal that appears on the J3 connector (J3-3 is signal and J3-4 is ground). It is connected to the J6 connector on the CNI board (J6-1 is signal and J6-2 is ground). The board also provides a regulated 5V, 100 ma supply on the TB3 terminal block (Pins-1 & 3 are positive and Pins-2 & 4 are ground). This supply may not be used in some assemblies. 2-35

54 2.6.2 AC Mains Power Supply Connection Power to the CNI is provided by stepping-down the AC mains voltage of 120Vac to 12Vac with a wall-mount transformer and using this voltage to source the power supply board. The power supply board then converts the 12VAC to multiple DC voltages that are used to run the CNI, MCM and ILI electronics as well as maintaining a charge on the lead-acid backup battery. WARNING Never apply 120VAC mains voltage directly to the supply board terminal block. This will result in a blown fuse and likely damage to the circuit board components. The transformer is mounted externally to the CNI and connects to the TB1 terminal block. See Figure 2-25 for an illustration of a typical transformer unit. It may be necessary to use an alternate transformer at sites where the AC mains voltage is different or to comply with the special safety requirements of a specific country. Figure 2-25 AC Mains Transformer 2-36

55 2.6.3 DC Power Supply Board Figure DC Power Supply Board Figure DC Power Supply Board There is one of two power supply boards used depending upon the age of the unit. The charging source for the power supply board is typically a 6-volt alkaline lantern battery. Any other filtered dc supply can be used as long as the voltage range is between 4.0 and 6.5 V. The battery connects to the TB2 connector (Pin-1 is positive and Pin-2 is ground). 2-37

56 The power supply board provides four functions. First, the board provides a regulated, low current (100mA) +4.2V supply for the CNI board. It is the primary power source when the radio is not being used and maintains the processor circuits and memory. This supply appears on the J3 connector of the power supply board (J3-1 is positive and J3-2 is ground). It connects to the J3 connector on the CNI board (J3-4 is positive and J3-1 is ground). When the radio is powered up the CNI generates a logic high signal on its J6 connector that causes the power supply board to turn on a high-current supply (J6-3 is signal and J6-2 is ground). This logic signal is connected to the J3 connector on the power supply board (J3-5 is signal and J3-6 is ground). The 12V high-current output appears on the J2 connector of the power supply board (J2-1 & 4 are positive and J2-2 & 3 are ground). The supply is connected to the TB2 terminal block on the CNI board (Pin-1 is positive and Pin-2 is ground). This supply provides the high current demanded by the radio. This supply voltage is regulated down to +5V on the CNI board. The third function is to supply a constant charging voltage for the lead acid battery. It is this battery that supplies most of the current for radio operations. The alkaline battery is simply a charging source. The lead acid battery is connected to the J1 connector (J1-2 is positive and J1-1 is ground). Nominal charging voltage is 13.5V. Finally the board monitors the condition of the alkaline battery and reports a low-battery condition to the CNI when the battery voltage reaches approximately 3.6V. This is a logic low signal that appears on the J3 connector (J3-3 is signal and J3-4 is ground). It is connected to the J6 connector on the CNI board (J6-1 is signal and J6-2 is ground). The board also provides a regulated 5V, 100 ma supply on the TB3 terminal block (Pins-1 & 3 are positive and Pins-2 & 4 are ground). This supply may not be used in some assemblies. 2-38

57 2.6.4 Installing or Replacing the Rechargeable Battery A 12V, 2.5Ahr sealed lead acid battery provides backup power and supports the brief but heavy current requirements of the cellular radio during transmissions. The lead acid battery is shipped separately to prevent damage to the electronic components and to satisfy regional rules regarding the shipment of hazardous materials. Figure 2-28 Installation of the rechargeable battery Once the battery is installed, locate the two-wire cable with the white connector that is plugged into J1 on the power supply board. Follow these steps: 1) Unplug the white connector from the J1 connector on the power supply board. Grasp and squeeze the ears on the connector, then pull out. 2) Connect the black wire to the negative (-) terminal on the battery. 3) Connect the red wire to the positive (+) terminal on the battery. 4) Do not plug the white connector back in until reading the rest of this chapter. 2-39

58 2.6.5 Model GSM18 CNI Board Layout The Model GSM18 CNI circuit board assembly is shown in Figure Figure 2-29 Primary Components of the Model GSM18 CNI Board 2-40

59 2.6.6 Model GSM20 CNI Board Layout The Model GSM20 CNI circuit board assembly is shown in Figure Figure 2-30 Primary Components of the Model GSM20 CNI Board 2-41

60 2.6.7 Model CDMA18 CNI Board Layout The Model CDMA18 CNI circuit board assembly is shown in Figure Figure 2-31 Primary Components of the Model CDMA18 CNI Board 2-42

61 2.6.8 CNI Board Block Diagram 2.7 CNI Board Jumper Settings Figure 2-32 Block Diagram of the CNI Board JUMPER POSITION NOTES J2 OPEN Momentary short will force the unit to originate a call JP3 A-B For applications that require the DSR control line to have RS- 232 voltage levels (± 9V). This is the required setting for CPM- 2 applications. JP3 B-C For applications that require the DSR control line to have +5V and 0V voltage levels. Not used in this application. JP4 OPEN Momentary short will reset unit and clear data memory JP7 OPEN Used for factory testing Table 2-10 CNI Board Jumper Configuration 2-43

62 2.7.1 Internal Antennas There are several types of internal antennas including the rigid radio-mounted one shown in Figure This antenna is specifically designed for 1900 MHz operation, which was the primary operating frequency in North America when the GSM system first began operation. Figure B-001 Single-Band Antenna The earlier analog cellular services started on the 850 MHz band. Analog services are now being phased out and the original 850 MHz band is being converted to digital operation by most carriers. The original CPMs (built prior to 2006) used a Motorola g18 GSM cellular radio module. Production of this device was discontinued in 2005 and was replaced by the g20. The original g18 radio supported three frequency bands, including 1900 MHz but not including the 850 band. The g20 radio supports two bands. One model supports 850 / 1900 MHz operation while another supports 900 / 1800 MHz. Metretek now offers a quad-band antenna to cover all cellular frequencies. This is shown in Figure If the cellular service being used operates on the 1900 MHz band only then either internal antenna can be used. Figure Quad-band Antenna An adhesive strip on the back of the antenna allows the antenna to be mounted to the inside wall of the enclosure. A short coaxial cable attaches to the radio s antenna connector. 2-44

63 2.7.2 External Antenna Kit You may encounter marginal reception areas or locations where buildings and other obstructions block the cellular radio signal path. The rigid internal antenna may not provide adequate performance in these situations. Provisions have been made to permit the installation of an external antenna kit, often mounted to the side of the enclosure. Figure 2-35 provides an exploded diagram of the components included with the kit. Metretek Stock # Frequency Usage MHz CDMA and GSM MHz GSM MHz GSM MHz CDMA and GSM Table 2-11 External Antenna Kits Figure 2-35 Optional External Antenna Kit Every CNI enclosure has been pre-drilled with a 1/4" diameter hole on the side of the enclosure wall. It is necessary to push out the small black hole plug and clean away any residual silicon sealant. The SMA female end of the cable is then pressed through the enclosure wall and fastened into place using the provided washer and nut. When securing the antenna onto the SMA connector, ensure that the fitting is tightened 2-45

64 sufficiently by hand (tools are not required), and that the antenna is vertically orientated. The opposite end of the cable with the MMCX connector end is pressed onto the mating connector of the Motorola cellular radio as shown in Figure Each model of the CNI uses a different radio. Although all radios use the same type of MMCX connector, they are located in different positions. Please note that the c18 CDMA radio has two connectors. It is important to install the cable into the right-hand connector. 2.8 Lead Acid Battery Testing / Replacement Cycle The lead acid battery provides the heavy but short duration current required by the cellular radio module during data transmissions, as well as serving as a backup source during AC power failures. Testing of the lead acid battery should be performed while the CNI is in service. Disconnection of the AC power transformer or alkaline charging battery is recommended during this test in order to obtain more accurate measurements. Using a voltmeter, take a measurement with the probes touching the lead acid connection terminals. A fully charged battery should measure about 12.6 volts when no cellular calls are being processed. During a cellular call placement, the voltage should not drop below 11.5 volts. If either of these measurements is too low then the battery should be replaced. A normal replacement cycle is approximately every 2 to 4 years. 2.9 Lithium Battery Testing / Replacement Cycle CPM-1 units include one or two lithium batteries to power the ILI boards. These are high-capacity 3.6V D cell arrangements with built-in protection devices. Only the same type of battery pack should be used as a replacement. A lithium battery generally maintains full voltage throughout its life. Near the end of life the voltage starts dropping dramatically. Any lithium battery measuring 3.3V or less should be replaced. The CPM-1 monitors the condition of these batteries and will report low battery conditions to the central computer. A low battery could result in inaccurate readings or no readings at all. Life expectancy for dual-channel units with only one lithium battery is approximately months. For single-channel units or dual-channel units with two batteries this increases to months. 2-46

65 3 CELLULAR SERVICE 3.1 GSM Service GSM Overview GSM is an abbreviation for Global System for Mobile communications. This communications standard is widely used throughout Europe, Africa, Asia and parts of North and South America. Messages are digitized into packets and sent in brief bursts during allocated time slots using a variation of TDMA (Time Division Multiple Access) techniques. Up to 8 cellular phones can thus share the same frequency band, which in turn permits the system to support more users with existing equipment. Efficient utilization of spectrum is an important consideration for service providers since there is only a limited bandwidth space that has been allocated to cellular phone service. Most GSM systems throughout the world operate on either the 900 MHz or 1800 MHz communications bands. In North America most GSM systems operate on the 1900 MHz band. Many older 850 MHz TDMA networks in North America are being converted for GSM service. The GSM20 covers both the 850 and 1900 MHz bands, and another version covers the 900 and 1800 MHz bands Establishing Cellular Service for GSM CSD A cellular account must be activated with the service provider prior to placing a CNI into service. Many GSM service providers offer some sort of data support, but their marketing focus may be on Internet connectivity or short-message services ( SMS, used to send text messages to and from cellular phones). This does not necessarily mean that they support all forms of data transfers. The service provider must support asynchronous circuit-switched data (CSD) exchange at 4800 or 9600 baud. The baud rate must match the baud rate of the central computer s modem. CSD may be included as part of a standard voice package, or it may be an add-on feature at extra cost. One consideration when ordering service is the frequency of calls to and from the CNI. Each service provider offers different packages that may include a fixed number of minutes per month for a fixed price. However, when this number is exceeded, the cost per each additional minute can be very high. There are also variations in the way minutes are measured. For example, a call lasting 1 minute 10 seconds may be considered to be a 2-minute call by some providers. It might be possible to purchase less expensive packages that have additional weekend or evening minutes, and then schedule the field device to call in at those times. Some plans may offer the 1 st minute free. This might be advantageous for short calls. Another consideration when ordering service is the location of the CNI with respect to the service provider s network. It is best to describe where the units will be located and where they will be calling, otherwise you could be charged roaming or long-distance fees. Some providers offer free long distance or no roaming charges as part of their basic plans. The final consideration is the direction of the calls. If the CNI is to originate calls, then 3-1

66 the service must support mobile-originate service. If the unit is to receive calls, then mobile-terminate service is required. Special provisions have been made to the CNI and the data collection software if mobile-terminate service is not available. The service provider will need the following information: Type of cellular service desired, which is circuit-switched data (CSD). The device type, which must be specified as the Metretek CNI / GSM18 or CNI / GSM20 Data mode is to support 4800 or 9600-baud operation. This rate must match the speed of central computer s modem. Mobile-originate and/or mobile-terminate service. Number of minutes per month. Location of the CNI and the location of central computer (to determine if roaming or long distance charges apply). The service provider may need to know the IMEI number printed on the radio SIM Card Installation for the GSM18 After the account has been established, the cellular service provider will provide a small memory card known as a SIM card (Subscriber Identity Module). Figure 3-1 illustrates the appearance of a SIM card. Figure 3-1 SIM Card Profile For the GSM18 the cellular radio module has a built-in SIM card holder. Care must be exercised to ensure that the electrical contacts of the SIM card will mate properly with the electrical contacts on the radio module. Figure 3-2 illustrates the location of the holder. Note the location of the notched corner on the SIM card. Never install a SIM card when power is present. 3-2

67 Figure 3-2 GSM18 SIM Card Holder Location SIM Card Installation for the GSM20 The SIM card holder for the GSM20 is located on the CNI board, near the radio. See Figure 3-3. Never install a SIM card when power is present. 3-3

68 Figure 3-3 GSM20 SIM Card Installation Requesting a Voice Phone Number or SMS Service As mentioned earlier some cellular service providers may not support the ability to place a data call to the CNI in CSD mode. This is called mobile-terminate service. Yet there may be times when it is desirable to communicate immediately with the CNI rather than wait for it to call in. To overcome these limitations the CNI supports the ability to be paged. When paged the CNI will immediately call back to the central computer. There are two ways to page, and these are described in Chapter-6. If the cellular account has been assigned a voice or data number then the unit can be called using this number. Otherwise most cellular providers can include SMS (short message service) as part of the package. This allows the CNI to be paged with a text message. The SMS address of the unit is often created using the voice or data phone number as part of the address, such as @myserviceprovider.net. 3-4

69 3.2 CDMA Service CDMA Overview CDMA is an abbreviation for Code Division Multiple Access communications. CDMA technology was originally developed for military applications but was eventually commercialized. This communications standard is widely used in North America and in some parts of Asia and South America. Rather than dividing calls into time slots like GSM, CDMA allows all users to transmit at the same time. Each call is accompanied by a unique digital code that allows it to be differentiated from the rest. As an analogy suppose you are in a crowded room and many conversations are taking place at the same time. Your brain is able to distinguish the conversation you are having with your friend because it is able to focus on your friend s voice characteristics. As the room grows more crowded each person must talk louder and the size of the conversation zone grows smaller. You may have to move closer to your friend to keep the conversation going. Thus the number of conversations is limited by the overall interference and noise in the room Establishing Cellular Service for CDMA CSD A cellular account must be activated with the service provider prior to placing a CNI into service. Many CDMA service providers offer some sort of data support, but their marketing focus may be on Internet connectivity or short-message services ( SMS, used to send text messages to and from cellular phones). This does not necessarily mean that they support all forms of data transfers. The service provider must support asynchronous circuit-switched data (CSD) exchange at the baud rate of the central computer s modem. Sometimes this capability may be included as part of a standard voice package, or it may be an add-on feature at extra cost. One consideration when ordering service is the frequency of calls to and from the CNI. Each service provider offers different packages that may include a fixed number of minutes per month for a fixed price. However, when this number is exceeded, the cost per each additional minute can be very high. There are also variations in the way minutes are measured. For example, a call lasting 1 minute 10 seconds may be considered to be a 2-minute call by some providers. It might be possible to purchase less expensive packages that have additional weekend or evening minutes, and then schedule the field device to call in at those times. Some plans may offer the 1 st minute free. This might be advantageous for short calls. Another consideration when ordering service is the location of the CNI with respect to the service provider s network. It is best to describe where the units will be located and where they will be calling, otherwise you could be charged roaming or long-distance fees. Some providers offer free long distance or no roaming charges as part of their basic plans. The final consideration is the direction of the calls. If the CNI is to originate calls, then the service must support mobile-originate service. If the unit is to receive calls, then 3-5

70 mobile-terminate service is required. Special provisions have been made to the CNI and the data collection software if mobile-terminate service is not available. The service provider will need the following information: Type of cellular service desired, which is circuit-switched data (CSD). The device type, which must be specified as the Metretek CNI / CDMA18. Data rate. This rate must match the speed of central computer s modem. Mobile-originate and/or mobile-terminate service. Number of minutes per month. Location of the CNI and the location of central computer (to determine if roaming or long distance charges apply). The service provider may need to know the ESN number printed on the radio. This is printed on a label on the c18 radio as shown in Figure 3-4. Make sure this number is correct. It consists of 8 digits and can consist of both numeric and alpha characters. The printing is small and it is often difficult to distinguish between a zero ( 0 ) and an upper-case D. Figure 3-4 Location of ESN number on the c18 radio Requesting a Voice Phone Number or SMS Service As mentioned earlier some cellular service providers may not support the ability to place a data call to the CNI in CSD mode. This is called mobile-terminate service. Yet there may be times when it is desirable to communicate immediately with the CNI rather than wait for it to call in. To overcome these limitations the CNI supports the ability to be paged. When paged the CNI will immediately call back to the central computer. There are two ways to page, and these are described in Chapter-6. If the cellular account has been assigned a voice or data number then the unit can be called using this number. Otherwise most cellular providers can include SMS (short message service) as part of the package. This allows the CNI to be paged with a text message. The SMS address of the unit is often created using the voice or data phone number as part of the address, such as @myserviceprovider.net. 3-6

71 3.2.4 Over-the-Air Activation Unlike GSM, CDMA technology does not support the use of a SIM card (Subscriber Identity Module) to hold and transport account information. Therefore the account information must be downloaded into the cellular module s own memory. This is sometimes accomplished by dialing a special phone number to request over-the-air activation (OTAA). The activation phone number is specific to the service provider and must be programmed into the CNI using the MP32 configuration software (Chapter-4). The OTAA process does two things. First, if this is the very first OTAA call, a new phone number is programmed into the phone. This is the number that can be used to page the unit via a phone or data call, or via an SMS message. It may also be the number to use when making a data call to the CNI ( mobile-terminate service). It also starts the account billing process. Second, a preferred roaming list (PRL) is downloaded into the phone. This instructs the radio which service providers to search for and connect to. If the CNI sees that the radio s phone number has not been assigned then the activation number is dialed and over-the-air activation is attempted. This also happens automatically whenever the unit is reset and then every 7 days thereafter. The reason for this is that cellular service providers often make arrangements with other providers to carry calls in areas where their own equipment and towers do not exist. These agreements allow the call to be forwarded at no additional charge. The preferred roaming list says that it is acceptable to connect with these carriers. However at some point your service provider may install new equipment in these areas, and the contract with the partner may be terminated. In this new situation roaming fees will be added to each call if the radio is allowed to connect to the other carriers. This is why it is important to periodically update the PRL. The OTAA call process is discussed in more detail in Chapter

72 3-8

73 4 CONFIGURATION USING METRETEK PROGRAMMER 4.1 Metretek Programmer Cable Before placing a CNI into service, it is necessary to setup certain configuration parameters. Setting up the configuration requires a computer, Metretek programmer (MP32) software and a special programming cable. These items are listed below: 80x86 or Pentium-based personal computer with an available 9-pin serial port (COM1, COM2). Minimum operating system is Windows 98. Windows -based Metretek Programmer software, MP32, available under Metretek P/N: The MP32 software should be version or later. PC-to-Remote Interface cable, Metretek P/N B-001. An illustration of the cable assembly was provided in Chapter-2, Figure 2-1. The CNI stores configuration information in its non-volatile memory. This information is not lost when power is removed or the unit is reset. Certain parameters are unique to each CNI, such as a phone number to call, cellular service details, etc. These parameters can be programmed prior to, during, or after installation of the device in the field, although it is normally most convenient to setup and test the configuration prior to installation. 4.2 MP32 Software Startup When MP32 is started it will require a user name and password. In this application use the default user name and leave the password blank. Figure 4-1 MP32 Login Screen After login a window will appear to allow you to select the type of Metretek device to program (Figure 4-2). Prior to selecting the device, select the Communication Configuration button. In the next window (Figure 4-3) select the Cable Comm Port as the default, and make sure that the selected port matches the port that the cable is plugged into on the computer, such as COM1, COM2, etc. Then select the OK button. 4-1

74 Figure 4-2 MP32 Start-Up Screen Figure 4-3 Communication Port Configuration Screen 4-2

75 4.3 Programming the CPM-2 The original MP32 screen will now reappear (Figure 4-2). If programming a CPM-1 go to Section 4.4. For the CPM-2 select the MARCICPM-2 button to start the configuration process. The next screen will appear: Figure 4-4 Main Configuration Screen for CPM-2 A configuration can be saved for future use by using the FILE pull-down menu (upper left-hand corner of the screen). A previously saved configuration can be opened in the same manner. This is useful when several units are to be programmed with similar information, such as the same destination phone number. To start a session either OPEN a previously saved configuration or perform a READ operation with the cable installed and the unit powered up. If the CNI is busy it may take up to 30 seconds to respond, so please be patient. The status of the operation is displayed on the bottom of the screen. The CANCEL button will terminate the session in the event there is no response. 4-3

76 4.3.1 Remote Unit ID Each CNI must have a unique ID number. Legal six-digit values are FFFFFF (hexadecimal notation). Sequential numbering is not required, nor is it necessary to use any of the hexadecimal digits A, B, C, D, E, or F Destination If the CNI is allowed to originate a data call to the central computer then it will need the phone number of the computer s modem. Select the Phone Number button and enter up to 32 numeric digits, including the # and * symbols. As with cellular phones, it is usually necessary to enter the entire phone number, including area code, even if the call is local. For example, in the U.S., a call to within area code 321 may have to be entered as or TeleCom Mode Three settings are possible in this field: Answer, Originate and Answer & Originate. These selections determine whether the unit is limited to only placing calls, only receiving calls or both. For the CNI-2 a special feature called a Relay Schedule requires that the unit be configured to answer calls, so the Answer & Originate setting is required for this mode. See more about this in Chapter Dialer Type This selection is only used for legacy wired phone line CPMs and has no effect on cellular products Operating Mode Three possible options are available: Metretek, Transparent, or Both. For the CNI-2 it is recommended that Both be selected for most applications. See Chapters-5 and 6 for more information Max BPS A Metretek MODSMOD modem (Modular Smart Modem) is required at the central computer site for retrieving data from the CNI. The chassis allows up to 8 Metretek modem cards to be installed and used simultaneously. The modem cards can support 1200, 2400 or 9600 bps transfer rates. The type of cards used depends upon the baud rates that are supported by the cellular service provider. Most GSM service providers no longer support rates below 9600 bps. The Models GSM18 and GSM20 do not support rates below The CDMA18 supports most common baud rates up to Selections are Auto, 300, 1200, 2400, 4800 and 9600 bits per second (bps). The AUTO selection is only used for legacy wired phone line CPMs and should not be selected for these cellular products Answer Ring Count This selection is only used for legacy wired phone line CPMs and has no effect on cellular products Firmware Version The firmware version is a value that is updated on the screen whenever a Read operation is performed. This is not a parameter that can be modified. 4-4

77 4.3.9 Primary Call Retry Rate If the CNI is programmed to originate a call, and the call is unsuccessful for any reason, it will try again at a later time. The CNI can be programmed to wait from 1 to 15 minutes between each attempt Primary Call Retry Count This is the number of times (15 maximum) the CNI will try to repeat a call at the Primary Call Retry Rate, discussed previously. After this, calls will be attempted at the Secondary Call Retry Rate, discussed next Secondary Call Retry Interval After the Primary Call Retry Count has expired, the Secondary Call Retry Interval defines the time between each additional attempt, in 1-hour increments up to a maximum of 15 hours. There is no limit to the number of times the CNI will attempt to place a call at this rate. Once a call is successful, the CNI will return to using the primary retry rate and count for the next unsuccessful call Counter/Status Input 1 Input #1 on the terminal block of the CNI board can be configured to be either a pulse counting input (Data) or an Alarm input. When configured as a pulse counting (Data) input, all other options will be disabled. If the input has been selected to be an Alarm, then the Alarm String Download check-box can be either enabled or disabled. When enabled, the Alarm Description field can be edited with a short text string that is meaningful to the user. Examples include Low Pressure, Power Failure, etc. See Chapter-6 for a more detailed description of how this feature is used Connect to on Input 1 Alarm If Input #1 is configured as an alarm, and the data collection software has programmed the CNI to place an immediate call when the alarm occurs (see Chapter-5), the phone number in this field will be used to place the call. The Phone Number entry field contains the same number as the Destination Phone Number field at the top center of the configuration screen. It is not possible to edit this field directly. To change it edit the Destination Phone Number Counter/Status Input 2 Input #2 on the terminal block of the CNI board can be configured to be either a pulse counting input (Data) or an Alarm input. Input #2 is only available as an Alarm input, and cannot serve as a pulse counting data input. It is possible to either enable or disable the Alarm String Download feature. When enabled, the Alarm Description field can be edited with a short text string that is meaningful to the user. Examples include Low Pressure, Power Failure, etc. See Chapter-6 for a more detailed description of how this feature is used Connect to on Input 2 Alarm If the data collection software has programmed the CNI to place an immediate call when Alarm-2 occurs (See Chapter-5), the phone number in this field will be used to place the call. This phone number can either be the same as the Destination Phone Number or 4-5

78 can be a different number for specialized applications. For example the second phone number could be the phone number of a field technician s pager. Select the Cellular Settings tab to continue the configuration. Figure 4-5 Cellular Settings Screen for CPM Service Type One of two options can be selected, GSM (for the GSM18 or GSM20), or CDMA (for the CDMA18) PIN Number (GSM18 or GSM20 only) GSM cellular radios require a memory card called a SIM card (Subscriber Identity Module), sometimes also called a Smart Card. This is issued to the cellular customer when the cellular service is purchased. A SIM holds information about the account so that certain services are made available to the customer. A SIM card can be moved to a different phone or radio, and the account information moves with it. Though convenient, this may encourage someone to steal the SIM card, insert it into his or her own cellular phone and make hundreds of hours of calls that will be billed to the owner of the card. 4-6

79 A personal identification number (PIN) as an extra security measure to prevent unauthorized use of a SIM card. The PIN number can range from 1 to 8 numeric digits long and can be assigned by the cellular service provider when the card is activated. If a PIN number is not used, leave the PIN Number field blank. Do not fill it with 0 s, because a 0 is a valid PIN digit. CDMA does not support the use of a PIN number Frequency (GSM18 only) Depending upon the service provider chosen and the region of the world in which the CNI is located, there will be a specific frequency band used for the cellular service. These are generally 850 or 1900 MHz in North America, and 900 or 1800 MHz elsewhere. The Models GSM20 and CDMA18 automatically determine the correct frequency, but the GSM18 needs a specific frequency OTAA Programming Number (CDMA only) Unlike GSM radios, CDMA radios do not use SIM (Subscriber Identity Module) cards to hold account information. After purchasing CDMA service it may be necessary for the radio to dial a special phone number to be activated and to have account information downloaded into the phone s memory. This phone number is specific to the carrier and must be entered into the OTAA Programming Number slot in MP32. OTAA means over-the-air activation. Not all carriers require this. See Chapters-3 & 6 for more information. If over-the-air-activation (OTAA) is not supported by the carrier, leave the OTAA Number field blank. 4-7

80 4.4 Programming the CPM-1 For the CPM-1 select the IMU, PT-II, CPM-1 button to start the configuration process. The next screen will appear: Figure 4-6 Main Configuration Screen for CPM-1 A configuration can be saved for future use by using the FILE pull-down menu in the upper left-hand corner of the screen. A previously saved configuration can be opened in the same manner. This is useful when several units are to be programmed with similar information, such as the same destination IP address. To start a session either OPEN a previously saved configuration or perform a READ operation with the cable installed and the unit powered up. If the CNI is busy it may take up to 20 seconds to respond, so please be patient. The status of the operation is displayed on the bottom of the screen. The CANCEL button will terminate the session in the event there is no response. 4-8

81 4.4.1 Remote Unit ID Each CNI must have a unique ID number. Legal six-digit values are FFFFFF (hexadecimal notation). Sequential numbering is not required, nor is it necessary to use any of the hexadecimal digits A, B, C, D, E, or F Destination If the CNI is allowed to originate a data call to another modem (CSD mode), then it will need the phone number of the modem. Select the Phone Number button and enter up to 32 numeric digits, including the # and * symbols. As with cellular phones, it is usually necessary to enter the entire phone number, including area code, even if the call is local. For example, in the U.S., a call to within area code 987 may have to be entered as If the CNI is to communicate via the Internet then it will need the IP address and port number of the InvisiConnect Server. Your computer system s administrator usually assigns these values. Select the IP Address button. Then enter the address of the server expressed in dotted decimal format, such as The port number must match the one assigned on the server. If the port number needs to be changed hold down the CTRL key on the keyboard, point to the port number box and double click the pointing device (ie mouse). Then enter a new port number Originate Calls Check this box if the CNI is allowed to originate CSD calls or Internet connections Respond to Voice Calls Check this box if the CNI is allowed to answer CSD calls, or is allowed to be paged using its voice phone number. See Chapter-6 for more information about paging. If this option is selected the radio will remain powered up at all times. This will greatly shorten battery life in battery-operated units. It may be necessary to use a constant dc power source or an ac-powered unit Respond to SMS Check this box if the CNI is allowed to be paged via SMS (short message service). See Chapter-6 for more information about paging. If this option is selected the radio will remain powered up at all times. This will greatly shorten battery life in battery-operated units. It may be necessary to use a constant dc power source or an ac-powered unit Maintain Internet Connection When the CNI originates an Internet connection, it must request access to the cellular provider s packet service, then access to the Internet and finally access to the destination server. All of this negotiation takes a certain amount of time. To reduce this time the CNI can maintain access to the Internet at all times and only needs to request access to the destination server, which only takes a few seconds. This is often referred to as an always on connection. 4-9

82 NOTE: To use this feature you must also check the Originate Calls checkbox. When maintaining an Internet connection it is not possible to answer incoming phone calls or SMS pages, so those selection boxes are disabled on the screen. If this option is selected the radio will remain powered up at all times. This will greatly shorten battery life in battery-operated units. It may be necessary to use a constant dc power source or an ac-powered unit Dual Port This selection allows two external RS-232 devices to be connected to the CNI using the optional dual-port multiplexer board described in Chapter-2. If the Dual Port box is checked then two other selections are enabled. The first selection is only used in CSD mode and allows the CNI to wait a certain number of seconds to receive a port select command from the central computer, which will be discussed in Chapter-6. If no command is received within this time frame, the CNI will select a port based on the second selection. The second selection is used in both CSD and Internet mode. The choices are Port-1, Port-2, Alternate or None. This is the port that will be selected for an incoming CSD call or if the unit is paged to call back to the central computer. If Alternate is selected then the port selection will alternate with every call. The first call will go to Port-1, the second call to Port-2, the third to Port-1 and so on. See Chapter-6 for more information Firmware Version The firmware version is a value that is updated on the screen whenever a Read operation is performed. This is not a parameter that can be modified by the user Primary Call Retry Rate If the CNI is programmed to originate a call, and the call is unsuccessful for any reason, it will try again at a later time. The CNI can be programmed to wait from 1 to 15 minutes between each attempt Primary Call Retry Count This is the number of times (15 maximum) the CNI will try to repeat a call at the Primary Call Retry Rate, discussed previously. After this, calls will be attempted at the Secondary Call Retry Rate, discussed next Secondary Call Retry Interval After the Primary Call Retry Count has expired, the Secondary Call Retry Interval defines the time between each additional attempt, in 1-hour increments up to a maximum of 15 hours. There is no limit to the number of times the CNI will attempt to place a call at this rate. Once a call is successful, the CNI will return to using the primary retry rate and count. 4-10

83 Counter/Status Input-1 For all versions of the CPM-1 select DATA for this input. This allows the CNI to process the data pulses from the first (or only) ILI board Counter/Status Input-2 For all dual-channel versions of the CPM-1 select DATA for this input. This allows the CNI to process the data pulses from the second ILI board. For single channel versions of the CPM-1 select ALARM for this input. This allows the CNI to report that the lithium battery is low and needs to be replaced. If the CNI is allowed to originate a call when an Alarm #2 condition occurs, you can define a different phone number or Internet address for this condition only. However, the destination doesn t necessarily have to be a computer. It might be the phone number of a pager, cell phone or warning device to alert someone of the situation. A special mode called Transparent Mode is discussed in detail in Chapter-6. In this mode, the CNI can send readable (ASCII) text strings to the caller or destination to describe the current status, such as *CUSTOMER ALARM-2 *. If this is desired, check the Alarm String Download box. You can also define a custom text string for Alarm #2 up to 20 characters in length. For example, Low Lithium Battery 4-11

84 Serial Port-1 Settings Select the SERIAL PORT 1 tab to continue the configuration. This screen is normally only used if an external RS-232 device is connected to the CNI s communications port. However, if making CSD calls, it also defines the baud rate used for those calls. Figure 4-7 Serial Port Configuration Screen for the CPM Port Select ID The Port Select ID for Serial Port #1 defaults to the remote unit ID (RUID) that was assigned to the CNI. It is shown on the SERIAL PORT 1 tab for reference and cannot be changed Max BPS This value must match the bit rate of the external RS-232 device. Important Note: If using circuit-switched data (CSD) service, the MAX BPS setting also sets the CSD bit rate. This is often referred to as bearer service. Many cellular service providers no longer support CSD baud rates below For the GSM18 and GSM20 the radio module used in the CNI does not support baud rates below If the 4-12

85 destination modem is a Metretek MODSMOD modem bank, you will need at least one 9600 baud modem card installed. For the CDMA18 most common baud rates up to 9600 are supported Data Bits This value must match the number of data bits used by the external RS-232 device Parity Type This value must match the type of parity used by the external RS-232 device Stop Bits This value must match the number of stop bits used by the external RS-232 device Serial Port-2 Settings If you have selected Dual Port mode (discussed earlier), then select the SERIAL PORT 2 tab to continue the configuration. All settings are identical to those for Serial Port 1 except for the Port Select ID. You must assign a unique ID number to the device connected to Port-2. This will allow the central computer to distinguish between the two devices. Legal six-digit values are FFFFFF (hexadecimal notation). Sequential numbering is not required, nor is it necessary to use any of the hexadecimal digits A, B, C, D, E, or F. 4-13

86 Cellular Settings Select the Cellular Settings tab to continue the configuration. Figure 4-8 Cellular Settings Configuration Screen for the CPM Service Type One of two options can be selected, GSM or CDMA. Each type requires a different version of the CNI board PIN Number (GSM only) GSM cellular radios require a memory card called a SIM card (Subscriber Identity Module). This is issued to the cellular customer when the cellular service is purchased. A SIM holds information about the account so that certain services are made available to the customer such as Internet access. A SIM card can be moved to a different phone or radio, and the account information moves with it. Though convenient, this may encourage someone to steal the SIM card, insert it into his or her own cellular phone and make hundreds of hours of calls that will be billed to the owner of the card. 4-14

87 A personal identification number (PIN) as an extra security measure to prevent unauthorized use of a SIM card. The PIN number can range from 1 to 8 numeric digits long and can be assigned by the cellular service provider when the card is activated. NOTE If a PIN number is not used, leave the PIN Number field blank. Do not fill it with 0 s, because a 0 is a valid PIN digit Frequency (GSM18 only) This field only applies to the GSM18. The GSM20 automatically determines which frequency band to use and ignores this setting. Depending upon the service provider chosen and the region of the world in which the CNI is located, there will be a specific frequency band used for the cellular service. These are generally 850 and 1900 MHz in North America, and 900 or 1800 MHz elsewhere GPRS Access Point Name (GSM only) This field only applies to GSM radios. If the CNI will be making an Internet connection the cellular service provider will need to provide an Internet APN (access point name). In order to connect to the Internet, the provider has its own computer equipment called a gateway server. The server will usually have an APN in the form of a domain name, such as myserviceprovider.com or a generic name such as proxy. Contact your service provider for this information. Service providers may have several different gateways to choose from, depending upon the type of service required. Web phones (cellular phones that support Internet access) are generally assigned to a gateway that only connects to WAP services (wireless application protocol). The CNI requires full Internet access because the data collection software could be running on any server located anywhere in the world. Full access gateways are usually assigned to customers who will be connecting a cellular modem to a personal computer Packet Service Connection Command This command is issued to the cellular network to request a packet (Internet) connection. For most GSM cellular service providers the phrase ATD*99# will work, and this is the default setting for the CNI in GSM mode. For most CDMA service providers the phrase ATD#777 will work, and this is the default setting for the CNI in CDMA mode. If you are having problems connecting, this could be the problem. Contact your service provider for more information. 4-15

88 OTAA Programming Number (CDMA only) Unlike GSM radios, CDMA radios do not use SIM (Subscriber Identity Module) cards to hold account information. After purchasing CDMA service it may be necessary for the radio to dial a special phone number to be activated and to have account information downloaded into the phone s memory. This phone number is specific to the carrier and must be entered into the OTAA Programming Number slot in MP32. OTAA means over-the-air activation. Not all carriers require this. See Chapters-3 & 6 for more information. If over-the-air-activation (OTAA) is not supported by the carrier, leave the OTAA Number field blank PAP User Name and Password As an added security measure some cellular service providers use Password Authentication Protocol, or PAP. In order to gain access to their Internet service you must present a user name and a password that was assigned when the cellular service was purchased. The user name or password can be any combination of printable ASCII characters, including spaces, such as Joe Smith or The total number of characters for both the user name and password cannot exceed 98 characters. The password is hidden on this screen for added security. You must enter the password twice to verify that it was entered correctly. NOTE If PAP is not required then both the user name and password fields must be blank. 4.5 Programming the CNI 1) Attach the 9-pin D-sub end of the PC-to-Remote Interface cable to an available serial communications port on the computer, such as COM1. 2) Attach the opposite end of the interface cable to the 4-position connector (J8) on the CNI board. The connector is keyed and can only insert in one direction. 3) Connect the lead acid battery s cable to J1 on the power supply board. The green PROGRAM MONITOR light should light solidly. The red RECEIVE DATA light should light momentarily, then go out. The green PROGRAM MONITOR light should then start flashing once per second. This indicates the CNI is running. 4) Once the parameters have been entered (or read in from a previously-saved configuration file), select the PROGRAM button to start programming the CNI. Status messages will appear in the lower left-hand corner of the screen. If the CNI is busy with radio operations, it could take up to 30 seconds to respond to the program command. If communications cannot be established within several minutes, check your cable and serial port, and try again. 4-16

89 5) When programming has completed, unplug the 4-pin connector of the serial cable from the J8 connector on the CNI board. Once the data collection software is configured (Chapter-5) the CNI will be ready to be put into service. 4-17

90 4-18

91 5 METRETEK DATA COLLECTION SYSTEM 5.1 Data Collection Modem For Circuit Switched Data (CSD) connections a Metretek MODSMOD modem (Modular Smart Modem) is required at the central computer site for retrieving data from the CNI. The chassis allows up to 8 Metretek modem cards to be installed and used simultaneously. The modem cards can support 1200, 2400 or 9600 bps transfer rates. These modems operate with a special error correction protocol that only accept errorfree data, and will request retransmissions for any corrupted data packets. Some Metretek modem cards are AT-compatible. Most GSM service providers no longer support rates below 9600 bps, and the GSM18 and GSM20 do not support rates below Therefore it will be necessary to install at least one 9600-baud card in the chassis. Though the radio in the CDMA18 supports all baud rates the service provider may not. Check with you service provider about this issue. 5.2 Data Collection Modem Emulator For packet (Internet) connections Metretek provides a software package called InvisiConnect Server which serves as a secure bridge between the Internet and the CPM data collection software. InvisiConnect emulates a MODSMOD modem. At the present time only the CPM-1 supports packet mode. Details about InvisiConnect will be presented near the end of this chapter. 5.3 Configuring the MODEM Channels Within the data collection software package is a program called Data Collection Initialization. Run this program and select COMMUNICATIONS from the top menu bar. 5-1

92 Figure 5-1 Modem Configuration Screen Configuring for a MODSMOD Chassis For CSD connections physical modems and phone lines are used. A Metretek MODSMOD chassis can contain up to eight modem channels. A breakout cable provides up to eight connectors that will be connected to as many serial communications ports on the central computer. Generally Channel-1 will connect to COM1, Channel-2 to COM2, etc. For each active channel select the YES button. There are several MODSMOD modem cards available. It is important to select the proper MODEM CARD TYPE for each channel. On each card there is a set of jumpers that configures the bit rate between the computer s COM port and the card. It is important to match the CONTROL TO SMOD BAUD RATE to this setting. It is recommended to use the highest rate available of

93 5.3.2 Configuring for an InvisiConnect MODSMOD Emulator For Internet connections the data collection software will communicate with the InvisiConnect MODSMOD emulator as though it were a physical modem device. InvisiConnect emulates one or many COM ports on the computer system. The data collection software believes it is communicating with actual hardware COM ports. For each active channel select the YES button. It is highly recommended to choose channels that are higher than any physical COM port in the computer. For instance if the computer has hardware ports for COM1 and COM2 then start with COM3 and up for the emulator. The MODEM CARD TYPE is ignored. Set thecontrol TO SMOD BAUD RATE to Details about InvisiConnect will be presented near the end of this chapter. 5.4 Configuration of the Data Collection Software Metretek s Cathodic Protection data collection software can accept calls from or place calls to hundreds of devices per hour, and processes the resulting data for later retrieval and inspection. Each CNI device needs to be identified, and certain parameters need to be defined prior to the first call. In this software package is an application called Remote Unit Manager. Figure 5-2 is the opening screen for the Remote Unit Manager: Figure 5-2 Opening Screen for Remote Unit Manager 5-3

94 5.4.1 Defining a New Device If an account has not been established for the CNI, select the ADD icon following window will appear:. The Figure 5-3 Defining a New Remote Unit There are several generic templates available for the CPM, or you can select a previously defined CNI as a template. If there are going to be several units with nearly identical configurations, it is best to define the first one using a generic template, and then use the first unit as a template for the remaining units. This will save time and typing. In Figure 5-3 a generic template was used for the 8-channel CPM-2. If you are using a CPM-1 device, choose the $CP1-2 template. Assign the same remote unit ID that was programmed into the unit using the Metretek Programmer software MP32 (see Chapter-4). The checkbox titled This remote can complete sessions originated by Host will be explained shortly in the discussion about Relay Configuration. You can change it later Defining Parameters for a CPM-2 NOTE Whenever making a change to a device, be sure to first highlight the device on the main screen (Figure 5-2) Configuring the Way Data is Collected and Stored Choose the Data Configuration icon at the top of the main screen. Note that most settings on this screen will not go into effect until the next communications with the CPM-2. The firmware version number will be retrieved from the CPM-2 and displayed on this screen. For most CPM-2 applications select the RUN mode. SLEEP mode is normally used in applications in which the equipment is running solely on batteries. 5-4

95 A time-tagged interval (TTI) reading consists of an average of one or more readings taken over the period of time defined by the Interval Resolution. The range is one every second to one every 24 hours, in predefined increments. Each TTI reading is stored in the CPM s memory and must be retrieved at some point; otherwise older data will be overwritten and lost. A smaller period allows small changes to be observed with more accuracy, but the memory will fill up more quickly. Figure 5-4 CPM-2 Data Configuration Screen The Input Sampling Rate determines how often samples are taken from each input and added to the total prior to averaging. This only applies to the RUN mode of operation. The range is once every 0.1 seconds to once every minute. Once an interval period has expired, the average is divided by the number of readings taken and is stored as the next TTI reading. If you ve chosen to use the SLEEP mode, the CPM-2 will wake up at the end of each interval, only acquire and store one TTI reading and will go back to sleep. Note that choosing too short of an interval may not allow the CPM-2 time to go to sleep, which defeats the purpose of this mode. 15 minute or greater intervals is recommended for SLEEP mode. Select YES or NO if you wish to record the time-tagged interval (TTI) and/or time-of-call (TOC) readings that are reported by the CPM-2. When the CPM-2 calls in you can choose one of three commands to send to the unit. The Status Only command instructs the CPM-2 to report alarm and status conditions but not send any TTI readings. This command usually results in the shortest call. The All Data command instructs the CPM-2 to send its status and its entire collection of TTI readings from the oldest to the newest. This command usually results in the longest call. 5-5

96 The Send Data From enables two other fields in which you can specify a starting date and time. The CPM-2 will search for a reading with this time stamp, or one that is closest and newer. It will then send all of the TTI data from that point forward to the present. If the date and time specified is newer than any reading, no records will be sent (same effect as issuing the Status Only command). If the date and time specified is older than the oldest reading in memory, all records are sent (same effect as issuing an All Data command). When the Send Data command is used, the data collection software will automatically fill in the next date and time stamp for the next call. There is no sense in retrieving data that was already retrieved on previous calls. But you can override this at any time. Select the OK button when finished. Use HELP for more information about each selection Defining the Input Channels Choose the Input Configuration icon at the top of the main screen. If you ve chosen to keep TTI and TOC readings then all data from all eight channels will be saved. If you wish to later view the data for a particular channel, check the Active box for that input. All other values are defaulted for a typical cathodic protection system, but can be changed as needed. The Jumper Configuration selection must match the jumper setting on the MCM board, otherwise the readings (and resulting decisions) may be incorrect. You can adjust each TTI reading using a Multiplier and Offset. For instance if a voltage signal has been divided by 2 before being connected to the CPM, then a multiplier of 2.0 will adjust the reading back to its true value. Figure 5-5 CPM-2 Input Configuration Screen 5-6

97 The Show Hardware Factors checkbox allows you to inspect each channel s gain and offset values and is normally only used for troubleshooting. Use HELP for an explanation of each selection. Then select the OK button Defining the Call Schedule Choose the Call Schedule icon at the top of the main screen. You can choose to have the CPM-2 call in at regular intervals using the Call Frequency selection boxes. Use care with this selection if your cellular account charges by the minute. The time and date of the last call appears near the top of the screen. Below that is the time and date of the next expected call based on the Call Frequency. This is automatically updated by the data collection system after each successful call. You can override this at any time, but the new time and date will not go into effect until the next communications with the CPM-2. Manual override is usually used to specify a specific starting time when a new unit is put into service. For instance you may want the unit to call in 08:05 each day, so you would specify a starting time of 08:05:00 for the first call and a frequency of 1 day. 5-7

98 Figure 5-6 CPM-2 Call Schedule Configuration Screen The Call-Out Phone Number is the phone number that is assigned to the cellular account by the cellular provider. If the cellular provider supports mobile-terminate CSD connections and you ve purchased this service, then enter the data number of the device and check the This remote can complete sessions originated by Host box. If mobile-terminate service is not available or has not been purchased, then enter the voice phone number of the account (if there is one) and do not check the This remote can complete sessions originated by Host box. This will be explained shortly in the discussion about Relay Configuration. The Call Now selection, when set to YES, will force the system to place an immediate call to the CPM-2. The data collection system will try the call several more times should a call fail. The selection will automatically be reset to NO by the system. The Channel selection box determines which of the eight MODSMOD modem channels will be used for the dial-out operation. Some cellular service providers no longer support slower legacy baud rates such as 1200 or 2400 baud. You may have several 1200 / 2400 cards in your chassis, along with a 9600-baud card. It is important to select a channel that will support the baud rate of the CNI. Use HELP for an explanation of each selection. Select the OK button when finished. 5-8

99 Defining the Alarm Inputs Choose the Alarms icon at the top of the main screen. The CNI can monitor and generate several alarm conditions. Most alarms can be configured to force an immediate call to the data collection computer by checking the Trigger Call on Alarm box. If not, they are reported at the next scheduled call-in time. You can apply a unique name to each alarm and the data collection system can be told to record these events in the database if the Log Alarm at Central box is checked. The two hardware inputs on the CNI board can be used as alarm inputs. Their names are defaulted to Customer Alarm 1 and Customer Alarm 2, but these can be changed. For instance, if one of the inputs is connected to a pressure switch, then the name could be changed to Pressure Too High!. Use HELP for an explanation of each selection. Then select the OK button. Figure 5-7 CPM-2 Alarm Configuration Screen 5-9

100 Defining Relay Schedules The MCM-II board has the ability to precisely control two external relays, often used to switch rectifiers in and out in cathodic protection systems. The Relay Configuration screen provides a high degree of control of these two outputs. Choose the Relay Schedule icon at the top of the main screen. Figure 5-8 CPM-2 Relay Configuration Screen You can define five different relay configurations that can be sent to the CPM-2 at any time. Each configuration can be activated or deactivated by checking the Allow Config. Transmit box. There is a checkbox for each relay. You can define the Initial State (ON or OFF) of each relay and specify when that state should begin. You can also define the Final State (ON or OFF) of each relay and specify when that state should go into effect. Toggle Mode allows the relays to automatically alternate states with a high degree of precision. When turned ON, you can specify how long to stay in the initial state and how long to stay in the opposite state. The relays will continue to alternate, or toggle, until 5-10

101 the time specified by the Final State time. Times are entered in 10 ths of a second. A value of 200 equates to 20 seconds. Toggle Mode also offers the ability to sample the analog inputs whenever the relays change state. This information is available as time-tagged interval (TTI) data. TTI data will only be recorded if the Interval Resolution is set for 1 hour, 4 hours or 24 hours. These three settings now define how long after the relays change state that a sample will be taken, as shown in Table 5-1. Interval Resolution Sample Delay Less than 1 hour No samples taken 1 hour 50 ms 4 hours 100 ms 24 hours 500 ms Table 5-1 Sample Delay for TTI Data in Relay Toggle Mode Finally, you can specify a time that the relay schedule will be sent to the CPM-2, which is called the Configuration Transmit Schedule. You can also have the schedule repeated for 2 or more days at the same daily times using the Transmit Consecutive Days box. NOTE The data collection software checks the Configuration Transmit Schedule every five (5) minutes. The next inspection time appears at the top of the screen. The Initial State time and Final State time must occur sometime after the Configuration Transmit Schedule is sent, or the relay schedule will be ignored. Here s an example. We want to toggle the relays starting with an Initial State of ON at 10:00:00 and a Final State of OFF at 12:00:00. We want the ON time to be 10 seconds and the OFF time to be 20 seconds (enter 100 and 200 for the Durations respectively). We want to give the system plenty of time to send this schedule to the CPM-2, so we set the Configuration Transmit Schedule to go out at 09:40:00. Here s an important note: The relay schedules are only sent when the data collection system calls the CNI. Therefore the CNI must be set for Answer and Originate mode when it is configured using the Metretek Programmer software MP32 (see Chapter-4). In the Add a Remote Unit and Call Schedule configuration screens, discussed earlier, there is a checkbox titled This remote can complete sessions originated by Host. To make the proper selection, it is necessary to know if the cellular service provider supports mobile-terminate CSD service, and if you ve purchased this service. Mobileterminate (MT) means that the remote unit can be called and data exchanged. Some service providers only support mobile originate service, meaning that the remote unit can place a data call but can t receive one. Or you may have elected not to purchase this service. GSM service providers that support MT often assign another phone number to the account specifically for data exchange, and sometimes will charge extra for the service. For CDMA units the same phone number is usually used for both voice and data service. 5-11

102 If MT service is available, check the This remote can complete sessions originated by Host box and enter the CNI s data phone number into the Call Out Phone Number in the Call Schedule configuration screen. If MT service is not available, a provision has been made to use the unit s voice phone number as a trigger ( page ) to call back for the relay schedule. Here s how this works. First, the cellular service provider should have assigned a normal voice phone number to the account. Enter the voice phone number into Call Out Phone Number in the Call Schedule configuration screen. Do not check the This remote can complete sessions originated by Host box. When it is time for a new relay schedule to be sent, the data collection software will call the CNI on its voice number. The CNI will answer the call, will attempt to establish a modem link (which can t be made) and will hang up after 30 seconds. This will trigger the CNI will call back within a minute. In the meantime the data collection software will also hang up and will then wait 4 minutes for the unit to call back. When the call is received, the relay schedule will be sent Synchronizing Relay Schedules for Multiple Units There may be multiple CPM-2 s located along a common structure such as a gas pipeline. They may be located many kilometers from each other and will be controlling their own local rectifier equipment. In some applications it may be necessary to have all units turn this equipment on or off at the same time. This requires that all units have their internal time-of-day clocks synchronized. Normally the time-of-day is taken from the computer s real-time clock. Historically the clock in a typical PC is not extremely accurate. The Metretek modem cards used in the MODSMOD chassis have more accurate clocks. When a special mode called Relay Sync Mode is used all units that receive a relay schedule will receive their time-of-day from the modem rather than the PC. Choose the Preferences will appear: icon at the top of the main screen. The following screen Figure 5-9 CPM-2 Preferences Screen 5-12

103 Check the box called Relay Sync Mode and select the OK button. Once this is selected the icon near the top of the screen will be colored red as a reminder that Relay Sync Mode is activated. Do not use the Relay Sync Mode indefinitely. The modem s clock and the PC s clock will eventually drift further apart, and this could start causing problems when scheduling next calls and when recording the time that calls were received. Generally the Relay Sync Mode should be used as long as a relay schedule is active, and then turned off when it has finished Defining Parameters for a CPM-1 NOTE Whenever making a change to a device, be sure to highlight the device first on the main screen (Figure 5-2) Configuring the Way Data is Collected and Stored Choose the Data Configuration icon at the top of the main screen. Note that most settings on this screen will not go into effect until the next communications with the CPM-1. The firmware version number will be retrieved from the CPM-1 and displayed on this screen. As discussed in Chapter-2, the ILI board produces a number of pulses per second, the rate of which is directly proportional to the signal being measured. A time-tagged interval (TTI) reading consists of the total number of pulses produced over the period of time defined by the Interval Resolution. The range is one minute to 60 minutes in predefined increments. Each TTI reading is stored in the CPM s memory and must be retrieved at some point; otherwise older data will be overwritten and lost. A smaller period allows small changes to be observed with more accuracy, but the memory will fill up more quickly. 5-13

104 Figure 5-10 CPM-1 Data Configuration Screen Select YES or NO if you wish to record the time-tagged interval readings that are reported by the CPM-1. When the CPM-1 calls in you can choose one of three commands to send to the unit. The Status Only command instructs the CPM-1 to report alarm and status conditions but not send any TTI readings. This command usually results in the shortest call. The All Data command instructs the CPM-1 to send its status and its entire collection of TTI readings from the oldest to the newest. This command usually results in the longest call. The Send Data From enables two other fields in which you can specify a starting date and time. The CPM-1 will search for a reading with this time stamp, or one that is closest and newer. It will then send all of the TTI data from that point forward to the present. If the date and time specified is newer than any reading, no records will be sent (same effect as issuing the Status Only command). If the date and time specified is older than the oldest reading in memory, all records are sent (same effect as issuing an All Data command). When the Send Data command is used, the data collection software will automatically fill in the next date and time stamp for the next call. There is no sense in retrieving data that was already retrieved on previous calls. But you can override this at any time. Select the OK button when finished. Use HELP for more information about each selection. 5-14

105 Defining the Input Channels Choose the Input Configuration icon at the top of the main screen. If you ve chosen to keep TTI readings then all data from both channels will be saved. If you wish to later view the data for a particular channel, check the Active box for that input. You can enter a text description for each channel. Select Transducer as the type of input As mentioned earlier each ILI board produces a number of pulses per second, the rate of which is directly proportional to the signal being measured. A time-tagged interval (TTI) reading consists of the total number of pulses produced over the period of time defined by the Interval Resolution. The data collection software can convert these timetagged interval (TTI) readings back into meaningful readings using a simple formula. As an example assume that the ILI has been configured for a full-scale range of 50V. The ILI board will produce 0 pulses for 0V and up to 5 pulses per second at 50V. Suppose over a 5-minute (300 second) period the final count is (final count) x (full scale range) Voltage = (Interval in seconds) x (pulses per second at full scale) (1100) x (50V) Voltage = (300 seconds) x (5 pulses per second) Voltage = 36.67V In this example a Multiplier of will produce the desired results. The Multiplier is calculated as follows: (full scale range) Multiplier = (Interval in seconds) x (pulses per second at full scale) (50V) Multiplier = (300 seconds) x (5 pulses per second) Multiplier =

106 Figure 5-11 CPM-1 Input Configuration Screen Defining the Call Schedule Choose the Call Schedule icon at the top of the main screen. You can choose to have the CPM-1 call in at regular intervals using the Call Frequency selection boxes. Use care with this selection if your cellular account charges by the minute. The time and date of the last call appears near the top of the screen. Below that is the time and date of the next expected call based on the Call Frequency. This is automatically updated by the data collection system after each successful call. You can override this at any time, but the new time and date will not go into effect until the next communications with the CPM-1. Manual override is usually used to specify a specific starting time when a new unit is put into service. For instance you may want the unit to call in 08:05 each day, so you would specify a starting time of 08:05:00 for the first call and a frequency of 1 day. 5-16

107 Figure 5-12 CPM-1 Call Schedule Configuration Screen The Call-Out Phone Number is the phone number that is assigned to the cellular account by the cellular provider. If the cellular provider supports mobile-terminate CSD connections and you ve purchased this service, then enter the data number of the device and check the This remote can complete sessions originated by Host box. If mobile-terminate service is not available or has not been purchased, or if the CPM-1 will be communicating via the Internet, then enter the voice phone number of the account (if there is one) and do not check the This remote can complete sessions originated by Host box. NOTE If the CPM-1 will be communicating via the Internet you must enter the entire phone number including area code. Also see Section 5.5 and for a discussion about how InvisiConnect uses this number. The Call Now selection, when set to YES, will force the system to place an immediate call to the CPM-1. The data collection system will try the call several more times should a call fail. The selection will automatically be reset to NO by the system. The Channel selection box determines which of the eight MODSMOD modem channels will be used for the dial-out operation. This applies for both physical modems and the InvisiConnect MODSMOD modem emulator. 5-17

108 For CSD connections some cellular service providers no longer support slower legacy baud rates such as 1200 or 2400 baud. You may have several 1200 / 2400 cards in your chassis, along with a 9600-baud card. It is important to select a channel that will support the baud rate of the CNI. Use HELP for an explanation of each selection. Select the OK button when finished Defining the Alarm Inputs Choose the Alarms icon at the top of the main screen. The CNI can monitor and generate several alarm conditions. Most alarms can be configured to force an immediate call to the data collection computer by checking the Trigger Call on Alarm box. If not, they are reported at the next scheduled call-in time. You can apply a unique name to each alarm and the data collection system can be told to record these events in the database if the Log Alarm at Central box is checked. For single-channel CPM-1s CUSTOMER ALARM 2 is used to report when the lithium battery is low. For dual-channel CPM-1s MAG SWITCH is used to report when one or both lithium batteries are low. You can change these descriptions to something more meaningful, like Low Lithium Battery. Use HELP for an explanation of each selection. Then select the OK button. Figure 5-13 CPM-1 Alarm Configuration Screen 5-18

109 5.5 Configuring the InvisiConnect MODSMOD Emulator For Internet connections the data collection software will communicate with the InvisiConnect MODSMOD emulator as though it were a physical modem device. InvisiConnect emulates one or many COM ports on the computer system. The data collection software believes it is communicating with actual hardware COM ports. Internet connections are only supported by the CPM-1. InvisiConnect also acts as one or more Internet servers on your computer and thus must be allowed access to the outside world. Most corporate computer systems use firewall technology to prevent unauthorized and potentially damaging access from outside sources. An Internet address must be assigned to InvisiConnect, and a port number must be assigned for each running server. These same numbers must be programmed into each CNI. To minimize potential invasion, InvisiConnect and each CNI exchange private information using a 64-bit data encryption standard. If this exchange fails InvisiConnect will terminate the connection immediately. When InvisiConnect starts the following basic screen will appear. Figure 5-14 InvisiConnect Main Screen 5-19

110 5.5.1 External IP Address This is the external Internet (IP) address that was assigned to InvisiConnect. This is the same address that was programmed into each CNI. Your computer system s administrator usually assigns this address. This is a traditional decimal IP address containing four octets, each of which cannot exceed the number IP Configuration and Control InvisiConnect can be configured to behave as one or more servers. A list of all currently defined servers appears in the Application Interface Type table. You will be selecting the MODSMOD modem Start All and Stop All When the Start All button is selected all servers will be started and the INVISICONNECT banner near the top of the screen will turn GREEN. The activity window on the righthand side will contain run-time information for each server. When the Stop All button is selected all servers will be halted and the INVISICONNECT banner near the top of the screen will turn RED. If the servers are currently connected to one or more remote devices, those connections will be terminated first Start / Stop You can start or stop an individual server by first highlighting that server name in the table and then selecting the Start / Stop button. If the server is currently connected to one or more remote devices, those connections will be terminated first.. If other servers are still running the INVISICONNECT banner near the top of the screen will turn ORANGE Deleting a Server Highlight the server s name in the table and then select the Delete button. You will be asked to confirm the selection before the server is actually deleted. If the server is currently connected to one or more remote devices, those connections will be terminated first Editing a Server You must first stop the server to be edited. If the server is currently connected to one or more remote devices, those connections will be terminated. Then highlight the server s name in the table and then select the Edit button Adding a Server Select the Add button to introduce a new server. 5-20

111 If adding or editing a server the next screen will appear: Figure 5-15 InvisiConnect Add / Edit Interface Configuration Screen User Application Interface Select MODSMOD Modem IP Port Number Though there is only one Internet address assigned to InvisiConnect you can have multiple ports assigned and a unique server running for each port. Your computer system s administrator usually assigns the port numbers. These numbers must match the destination port numbers that are programmed into each CNI. 5-21

112 Server Description You can assign a different label to each server that more clearly defines the application Auto Start Server at Startup If you check this box then the server will start automatically whenever you launch InvisiConnect. Otherwise use the Start / Stop or Start All buttons to manually start a server. All other settings can be left at their default settings. Select OK when finished COM Port Configuration InvisiConnect is a serial communications port emulator. Though the data collection software program may think it is communicating with a physical hardware port, it is actually communicating with a virtual port. You can define as many ports as you need, starting with COM5. COM1 to COM4 are reserved for actual hardware ports on the computer. If you have more than one server defined, first highlight the desired server on the main screen. Now you can add new ports, edit existing ports or delete ports by selecting the appropriate button near the bottom left side of the main screen. For our example we will ADD some new COM ports. The following setup screen will appear: Figure 5-16 InvisiConnect Serial COM Port Configuration Screen 5-22

113 One or more COM ports can be activated. To activate several COM ports at once check the Add Range box and enter the starting and ending COM port numbers. COM ports start at COM5 because most personal computers have accommodations for four physical COM port interfaces, and those ports might still be needed for other applications. However, if additional physical COM ports are installed (such as COM5), then you must not select them for use by InvisiConnect. If only one port is needed leave the Add Range box unchecked and select the desired COM port number. NOTE: The COM port(s) selected must match those selected in the data collection software configuration program, as discussed in Section 5.3. All other settings can be left at their default settings. Select OK when finished SMS (Paging) Configuration Every device connected to the Internet has an Internet protocol ( IP ) address. Devices with static IP addresses are typically servers that are always on and always ready to accept a request for communications. Their addresses are well known. InvisiConnect is a server. Other devices, typically called clients, are assigned temporary or dynamic addresses that are only valid during the connection. For security reasons the CNI only operates as a client and therefore can only originate a request for an Internet connection. It cannot be contacted directly via the Internet. As discussed earlier and in Chapter-6, paging is a way to signal the CNI to call back to the central computer. If a physical modem were present it could be used to dial the CNI s phone number, which would be interpreted as a page by the CNI. InvisiConnect does not have the necessary hardware to dial a phone number. However it can page the CNI by sending it a text message using a service called SMS, or short-messageservice. These messages are not sent via the Internet but over a radio channel designated to carry Unstructured Supplementary Services Data (USSD). When the CNI receives an SMS message it will immediately call back to the primary IP address and port number that has been programmed into the unit by MP32. There are several ways to send an SMS message to the CNI. A message can be sent using the same server that you normally use to send s to friends and business associates. This is known as an SMTP server (Simple Mail Transfer Protocol). However some cellular service providers only allow messages to be sent from one mobile device to another and not from other devices such as computers or PDAs. Contact your service provider for more information. In this case you can attach a cellular modem to the computer and use it to send the SMS message. A cellular modem is considered a mobile device. A computer that is running InvisiConnect but doesn t have access to an SMTP server or a cellular modem can send the message to another InvisiConnect computer that does. That computer can then send the message to the remote device. This is a special feature known as the Echo / Relay / API Server. 5-23

114 In many cases the SMS address of a mobile device consists partly of the device s telephone number. For instance, if the phone number is (909) then thesms address might look like @myserviceprovider.net. As discussed in Section (Defining the Call Schedule) the data collection software can be configured with the CNI s phone number and can perform a dial out operation. Instead of dialing a phone number InvisiConnect will construct the correct SMS address for the CNI and will send it a text message. It is worth noting that SMS is a low-priority feature on some networks and they may not be delivered immediately. The SMS/USSD Configuration feature helps InvisiConnect to formulate the correct SMS address. Select SMS/USSD Configuration from the Options pull-down menu or select the icon near the top of the screen. Figure 5-17 SMS/USSD Settings Screen 5-24