IntelliSAW CAM-5 User Manual

User Manual
910.00382.0001
May 2018
IntelliSAW CAM™-5
Condition Asset Monitoring
User Manual
910.00382.0001 May 2018
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Contents
Contents ........................................................................................................................................................ 3
Important Information .................................................................................................................................... 6
Section 1 Introduction ................................................................................................................................ 7
1.1 Models ........................................................................................................................................... 7
1.2 Instructions for Use ....................................................................................................................... 8
1.3 System Inputs and Outputs ........................................................................................................... 8
1.4 Labeling ......................................................................................................................................... 9
1.4.1 Back Label ................................................................................................................................. 9
1.4.2 Serial Number, Safety and Compliance Label ........................................................................ 10
Section 2 Installation ............................................................................................................................... 11
2.1 Unpacking ................................................................................................................................... 12
2.2 Dimensions.................................................................................................................................. 12
2.3 Connectors .................................................................................................................................. 13
2.3.1 Power Connector..................................................................................................................... 15
2.3.2 Chassis Ground Connector – Protective Earth ....................................................................... 16
2.3.3 Ethernet Connector ................................................................................................................. 16
2.3.4 USB Mini-B Cable Connector .................................................................................................. 16
2.3.5 USB Standard-A Connector .................................................................................................... 16
2.3.6 SD Micro Connector ................................................................................................................ 17
2.3.7 SCADA Connectors................................................................................................................. 17
2.3.8 Devices Connector .................................................................................................................. 18
2.3.9 SMA (RF) Connectors ............................................................................................................. 18
2.3.10 Humidity Sensor Connector ................................................................................................ 18
2.3.11 Relay Alarm Connector ....................................................................................................... 19
2.4 Panel Mounting ........................................................................................................................... 20
2.4.1 Installation Location ................................................................................................................ 20
2.4.2 Panel Cutout............................................................................................................................ 20
2.4.3 Mounting Bracket Installation .................................................................................................. 20
Section 3 Wiring ...................................................................................................................................... 22
3.1 Power Connection ....................................................................................................................... 24
3.1.1 Input Power Details ................................................................................................................. 24
3.1.2 Protective Earth (PE) wiring .................................................................................................... 26
3.2 RS485 Communication (Device and SCADA) ............................................................................ 26
3.2.1 CAM-5 Connection to Readers ............................................................................................... 27
3.2.2 CAM-5 Connections to External SCADA ................................................................................ 28
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3.2.3 RS485 Cabling ........................................................................................................................ 28

3.2.4 Bus Termination ...................................................................................................................... 29
3.2.5 Bus data rate (baud rate) considerations ................................................................................ 29
3.3 Humidity Sensor Connections ..................................................................................................... 29
3.4 Air Interface Connections ............................................................................................................ 30
3.5 Alarm Wiring ................................................................................................................................ 31
3.6 Example Wiring Diagram ............................................................................................................ 33
Section 4 HMI Overview .......................................................................................................................... 34
4.1 Home Screen .............................................................................................................................. 34
4.1.1 Home Screen Segments ......................................................................................................... 34
4.1.2 HMI Warning & Alarm Indications ........................................................................................... 36
4.1.3 Unit Details & Measurement Selection.................................................................................... 38
4.1.4 Versions .................................................................................................................................. 38
4.1.5 Network ................................................................................................................................... 38
4.1.6 Capture & Log Files ................................................................................................................ 39
4.1.7 Reboot ..................................................................................................................................... 39
4.1.8 Date ......................................................................................................................................... 39
4.2 Device Specific Detail Screens ................................................................................................... 40
4.2.1 Device Detail Screen Overview ............................................................................................... 40
4.2.2 Temperature Measurements ................................................................................................... 42
4.2.3 Humidity and Ambient Temperature ....................................................................................... 44
4.2.4 Partial Discharge ..................................................................................................................... 46
Section 5 HMI Configuration ................................................................................................................... 50
Section 6 Measurement Configuration & Sensor Installation .................................................................. 51
6.1 Measurement Configuration ........................................................................................................ 51
6.2 Sensor Installation ....................................................................................................................... 52
Section 7 SCADA System Integration ..................................................................................................... 53
7.1 Modbus RTU or TCP ................................................................................................................... 53
7.1.1 MODBUS COMMANDS .......................................................................................................... 53
7.1.2 MODBUS REGISTERS ........................................................................................................... 54
7.2 DNP3 ........................................................................................................................................... 57
7.2.1 DNP3 flags .............................................................................................................................. 58
7.2.2 DNP3 Settings ......................................................................................................................... 58
7.2.3 DNP3 TLS and Secure Authentication .................................................................................... 58
7.3 IEC 61850 ................................................................................................................................... 58
7.3.1 Logical Nodes List ................................................................................................................... 58
7.3.2 Mapping of Modbus to IEC61850............................................................................................ 59
7.3.3 Mapping of Digital Output to IEC61850 .................................................................................. 61
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Section 8 Specifications .......................................................................................................................... 62

Section 9 Product Certifications .............................................................................................................. 66
9.1 Compliance Testing .................................................................................................................... 66
9.2 Wireless Certifications ................................................................................................................. 67
9.2.1 Telecommunication Compliance ............................................................................................. 67
9.2.2 Approved Antennas ................................................................................................................. 67
9.2.3 Federal Communications Commission (FCC) ........................................................................ 68
9.2.4 Industry Canada (IC) ............................................................................................................... 68
Contact ........................................................................................................................................................ 70
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Important Information
This symbol identifies messages in this document related to safety.
DANGER
DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or
serious injury.
Failure to follow the instructions given will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation, which, if not avoided, could result in death or
serious injury.
Failure to follow the instructions given can result in death or serious injury
CAUTION
CAUTION indicates a potentially hazardous situation, which, if not avoided, may result in minor or
moderate injury.
Failure to follow these instructions can result in personal injury.
NOTICE
NOTICE alerts you to practices unrelated to personal injury, such as those that can cause property
damage.
Failure to follow these instructions can result in property damage.
IMPORTANT
IMPORTANT indicates additional information about making effective use of this product.
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Section 1 Introduction
The IntelliSAW CAM™-5 provides a local human machine interface (HMI) with remote monitoring
capabilities (temperature, partial discharge, and humidity / ambient temperature), data trending and
alarming, data aggregation, and multiple communication interfaces such as Modbus TCP, DNP-3, and
IEC61850 to integrate into existing SCADA / DCS systems.
The CAM-5 can be a stand-alone system ideal for predictive condition-based monitoring of electrical
power critical assets such as switchgear, generator circuit breakers, and bus ducts.
This manual covers CAM-5 functionality, configuration, safety, and installation.
1.1 Models
The following tables outline available CAM-5 models.
Model Number Description

CAM5 Base:
- Monitoring: Temperature, PD, Ambient Temp &Humidity
- Alarm outputs – 6 ch. (NO/NC)
CAM5B-TPH-AMEU - Multiunit Device Interface (RS485)
- Communication interface: Ethernet
- Standard communication: Modbus TCP
- Universal Input Power (100 to 250 VAC; 120 to 250VDC1)
CAM5 Base:
- Monitoring: Temperature
CAM5B-T00-AMEU - Multiunit Device Interface (RS485)
CAM5 Base:
- No Monitoring
CAM5B-000-AMEU - Multiunit Device Interface (RS485)
CAM5 Base:
- Monitoring: Temperature, PD, Ambient Temp & Humidity
CAM5B-TPH-AMFU - Multiunit Device Interface (RS485)
- Communication Interface: Fiber Optic (100 base FX)
- Standard communication: Modbus
CAM5 Base:
- Monitoring: Temperature, Ambient Temp &Humidity
CAM5B-T0H-AMEU - Multiunit Device Interface (RS485)
1 DC operation has not been evaluated for FCC Part 15 or c/UL/IEC 61010-1.
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1.2 Instructions for Use

The CAM-5 is intended to be installed in the Low Voltage compartment of switchgear or in similar types of
assets. The CAM-5 is intended for use at a maximum altitude of 5km, between -25°C to +70°C (+55°C at
250VAC input) and between 10 - 95% non-condensing relative humidity.
WARNING
THE CAM-5 IS INTENDED ONLY FOR INSTALLATION IN LOW VOLTAGE CONTROL
COMPARTMENTS.
ONLY SENSORS AND AIR INTERFACES ARE INTENDED FOR INSTALLATION IN MEDIUM / HIGH
VOLTAGE COMPARTMENTS.
ONLY WIRELESS SENSORS ARE INTENDED FOR CONTACT WITH ENERGIZED CONDUCTORS
ABOVE 300VRMS.
1.3 System Inputs and Outputs

The maximum system inputs and outputs are as follows:
Inputs Outputs
12 SAW wireless temp sensors Communications:
4 air interfaces (TMP or TPD) Modbus RTU (SCADA)2
Modbus TCP
8 humidity sensors (series connected) DNP3
Modbus RTU (Devices) IEC61850
Email alarms3
SMS alarms4
Power: 100 to 250V AC 50/60 Hz (20W) Alarms: 6 Form C (NO / NC) relays with a
120 to 250V DC1 shared common (COM)
2 MODBUS RTU output requires a non-standard model with RS485 communications card.
3 Email alarms require connectivity to a user-supplied SMTP server and valid email account for sending data.
4 SMS is only supported via a compatible cellular gateway device with a user-supplied SIM card and plan.
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1.4 Labeling
The CAM-5 has two identification labels. The back label provides model number and device specific
connections. The safety and compliance label on the top provides product serial number, certification
information and installation ratings.
1.4.1Back Label
The back label is unique per model number as the connectors will change. Each label identifies the unit
model number.
Figure 1: Example CAM-5 back label
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1.4.2Serial Number, Safety and Compliance Label

The safety and compliance label located at the top of the unit provides the product serial number,
manufacturer information, compliance information, along with input supply, installation, and alarm relay
ratings.
Figure 2: CAM-5 Safety and Compliance Label
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Section 2 Installation
WARNING
INSTALLATION AND CONFIGURATION SHOULD BE PERFORMED ONLY BY PERSONNEL WHO
ARE TECHNICALLY COMPETENT AND AUTHORIZED TO DO SO. LOCAL REGULATIONS
REGARDING ELECTRICAL INSTALLATION AND SAFETY MUST BE OBSERVED.
WARNING
THE USE OF THIS EQUIPMENT IN A MANNER NOT SPECIFIED IN THIS MANUAL OR BY THE
MANUFACTURER MAY IMPAIR PROTECTION OF THE USER AND EQUIPMENT.
CAUTION
THIS EQUIPMENT IS DESIGNED FOR INSTALLATION IN AN ENCLOSURE THAT PROVIDES
ADEQUATE PROTECTION AGAINST ELECTRIC SHOCK.
Failure to follow these instructions can result in personal injury.
NOTICE
The product is recognized as a component under c/UL/IEC 61010-1 and c/UL/IEC 61010-3 and has
been evaluated under IEC61000-6-5 in type 4 interface applications. The 61010-1 and -3 component
recognitions assume the following, which were not specifically evaluated for the product as a
component:
• Spacing of all wired components from energized conductors meets the greater of double
insulation under c/UL/IEC61010 or the BIL requirements of the host equipment.
• Wired sensors are installed and cabled in accordance with instructions.
Note that introduction of a recognized component into a previously recognized system requires
evaluation of the modified system for c/UL recognition.
Failure to follow these instructions can result in operation outside the c/UL recognition of the
product and/or host equipment.
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2.1 Unpacking
1. Remove the product from its packing. Retain the packing for future use, to transport the
instrument to a different site or to return it to the supplier for repair/testing.
2. Examine the delivered items for damage or defects. If any are found, contact the courier
immediately.
3. In the Box:
a. CAM-5 Unit
b. Power terminal block (2 position 7.62mm Plug)
c. Devices terminal block (6 position 3.5mm Plug) if option exists
d. SCADA terminal block (6 position 3.5mm Plug) if option exists
e. Alarm terminal block (5 position plug) if option exists
f. 16GB USB Flash Drive
g. (4) Mounting Clips
2.2 Dimensions
The CAM-5 HMI instrument has front screen dimensions of 153.4 mm W x 110.2 H with a face depth of
3.14 mm. The Body dimensions of the CAM-5 are 143.6 W x 100.25 H x 101.6 mm D.
Figure 3: CAM-5 Dimensions (in mm)
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2.3 Connectors
The product has up to fourteen connectors (depending on model):
Standard Connectors:
• (1) Input Power Connector

• (1) USB connector (Mini-B) – used for measurement configuration
• (1) USB connector (Standard-A) – used for data logging
• (1) SD Micro card – for factory and future use.
• (1) Ethernet Connector (system)
• (1) Ground lug – chassis ground
Optional Connectors:
• (4) SMA (RF) connectors – used for air interface connections

• (1) Alarms Connector
• (1) Devices (RS485) Connector –Reader Input through Modbus RTU
• (1) Humidity connector
• (1) SCADA Connector
o RS485 - integration through Modbus RTU
o Fiber Connector
o Ethernet Connector
Ethernet (system) USB-Mini-B USB-Standard-A
Humidity
Alarms Ground Lug
Power
SMA (RF)
Ports
DEVICES
Figure 4: CAM-5 Back View SCADA
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Ventilation
SD Card
RF Card LED
Mounting Clip
Slots
Mounting Clip
Figure 5: CAM-5: Left Side View Slots
IMPORTANT
External radio frequency energy sources located close to the RF ports can reduce the sensitivity of
partial discharge measurements.
IMPORTANT
The status LED of the RF card is visible through the ventilation slots.
LED States:
• No Illumination: No Power to RF measurement card

• Solid Green: Power, no measurements
• Green / Amber toggle: Automated measurements enabled
• Fast flashing Amber: Rebooting
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Ventilation
Mounting Clip
Slots
Figure 6: CAM-5: Right Side View
WARNING
INSERTION OF WIRES OR FINE TOOLS INTO THE VENTILATION SLOTS COULD RESULT IN
HAZARDOUS CONDITIONS.
2.3.1Power Connector
Pin Name Description
Line / (+) Line 1, DC+ Input power range:

100 to 250V AC and 120 to 250V DC1.
Neutral / (-) Neutral, Line 2, DC- 2-Phase AC uses (N / -) as Line 2
Line and Neutral are symmetric in the CAM™-5 and DC power may be applied at either polarity.
Line and Neutral have differential mode filtering and clamping to PE stud and have common
mode filtering and isolation to the remainder of the unit.
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2.3.2Chassis Ground Connector – Protective Earth

Interface Name Description
Chassis ground / protective earth lug connection, required for

Lug Protective Earth
safety when air interfaces are near energized conductors.
2.3.3Ethernet Connector
Used for configuration and Ethernet communication (10/100
RJ45 Ethernet (ETH-1)
BASE-T)
2.3.4USB Mini-B Cable Connector

Mini-B CNFG USB Mini-B used for unit configuration
2.3.5USB Standard-A Connector

USB Host-A used for image capture and data storage. Also used
Host-A USB
for software and configuration file uploads.
WARNING
THE CAM-5 IS DESIGNED TO ISOLATE THE USB PORTS FROM HAZARDOUS CONDITIONS
INTRODUCED FROM INCOMING CABLES AND THE ENERGIZED EQUIPMENT.
IT IS NOT ADVISED TO USE THESE PORTS OTHER THAN AS FOLLOWS.
• USB-MINI-B: SHORT TERM USE FOR CONFIGURATION AND VERIFICATION. NOT FOR
LONG TERM DATA COLLECTION.
• USB-HOST-A: LONG TERM DATA LOGGING WITH INFREQUENT REMOVAL AND
REPLACEMENT FOR DATA COLLECTION.
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2.3.6SD Micro Connector

SD Micro SD Micro SD card for factory use only
2.3.7SCADA Connectors
SCADA interface is determined by model number.
2.3.7.1Modbus RTU Connector

DATA- DATA Negative Negative Input for Modbus RTU (RS485)
DATA- DATA Negative Redundant Negative Input for Modbus RTU (RS485)
DATA+ DATA Positive Positive Input for Modbus RTU (RS485)
DATA+ DATA Positive Redundant Positive Input for Modbus RTU (RS485)
D-COM DATA Common Common input for Modbus RTU (RS485)
D-COM DATA Common Redundant Common input for Modbus RTU (RS485)
2.3.7.2Ethernet Connector
RJ45 Ethernet (ETH-2) Used for SCADA communication (10/100 BASE-T)
2.3.7.3Fiber Connector
LC FIBER (100Base-FX) Used for SCADA communication
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2.3.8Devices Connector
Redundant terminals are provided for ease of use, for daisy chaining RS-485 where the CAM-5 is not the
last device on the network. Where it is the last device, a ½ Watt 120 Ohm resistor should be placed
between one Data+ and Data–.

DATA- DATA Negative Negative Input for Modbus RTU (RS485)
DATA- DATA Negative Redundant Negative Input for Modbus RTU (RS485)
DATA+ DATA Positive Positive Input for Modbus RTU (RS485)
DATA+ DATA Positive Redundant Positive Input for Modbus RTU (RS485)
D-COM DATA Common Common input for Modbus RTU (RS485)
D-COM DATA Common Redundant Common input for Modbus RTU (RS485)
2.3.9SMA (RF) Connectors

P1 RF Port 1 Air Interface Radio Frequency Port 1
2.3.10 Humidity Sensor Connector

H-PWR Humidity Power Humidity Cable Power Input from Humidity Sensor
H-DAT Humidity Data Humidity Cable DATA Input from Humidity Sensor
H-CLK Humidity Clock Humidity Cable Clock Input from Humidity Sensor
H-COM Humidity Common Humidity Cable Common Input from Humidity Sensor
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2.3.11 Relay Alarm Connector

A-COM Alarm Common Common output for Alarms Connector
A-NO1 Alarm Output 1 Normally Open Alarm Output 1
A-NC1 Alarm Output 1 Normally Closed Alarm Output 1
A-COM may be high side with grounded loads (current source through relays) or may be low side with
powered loads (current sink through relays).
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2.4 Panel Mounting

CAUTION
ENSURE THE INSIDE OF THE PANEL IS WITHIN THE CAM-5 OPERATING

TEMPERATURE AND THERE IS ADEQUATE AIR FLOW TO PREVENT OVERHEATING.
2.4.1Installation Location
The CAM-5 is intended for indoor use and installation in weather protected enclosures such as
switchgear low voltage compartments or low voltage control boxes. If CAM-5 is being used as a
measurement device, location must be such that it does not exceed the maximum air interface cable
length (assuming cable routing). Reference the (910.00379.001) IntelliSAW Sensor Installation
Manual for more details. The CAM-5 can only be mounted horizontally.
2.4.2Panel Cutout
The CAM-5 requires a 144.9 mm W x 101.65 mm H panel cutout.
2.4.2.1Recommended Spacing
It is recommended to allow at least to 5 cm (2 in.) the rear of the CAM-5 HMI for connectors. Spacing on
the sides and below the unit should be at least 5cm (2 in.) for ventilation and should be increased if
adjacent meters also require ventilation. The spacing requirements should be considered to be additive
between instruments.
2.4.3Mounting Bracket Installation

Do not affix the mounting screws and brackets until the CAM-5 is inserted into the panel cut-out. The
CAM-5 will hold itself in the panel cut-out while the mounting clips are prepared and inserted. Insert the
clip into the pair of retention slots and tighten the retention screw.
Figure 7: CAM-5 lower two mounting clips.
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Figure 8: CAM-5 lower left and right mounting clips.
Figure 9: CAM-5 mounted with PE wire to earthed panel.
Safety requires a wire meeting local earth ground requirements for protective earth. Best EMC and EMI
results are achieved with a 10” (25cm) or shorter wire length to a nearby panel stud or bonded terminal.
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Section 3 Wiring
WARNING
SYSTEM WIRING SHOULD BE PERFORMED ONLY BY PERSONNEL WHO ARE TECHNICALLY
COMPETENT AND AUTHORIZED TO DO SO. LOCAL REGULATIONS REGARDING ELECTRICAL
INSTALLATION AND SAFETY MUST BE OBSERVED.
WARNING
TO AVOID ELECTRICAL SHOCK. AC POWER WIRING MUST NOT BE CONNECTED TO THE
SOURCE UNTIL ALL WIRING CONNECTIONS PROCEDURES ARE COMPLETED.
WARNING
CHECK THE INFORMATION LABEL ON THE CASE TO DETERMINE THE CORRECT VOLTAGE
BEFORE CONNECTING TO A LIVE SUPPLY.
WARNING
SYSTEM EVALUATION AS A RECOGNIZED COMPONENT DOES NOT CONVEY RECOGNITION
TO THE END EQUIPMENT INTO WHICH THE SYSTEM IS INSTALLED.
PROFESSIONAL INSTALLER OR OEM IS RESPONSIBLE FOR ALL CODE AND SAFETY

REQUIREMENTS ASSOCIATED WITH SENSOR AND ANTENNA PLACEMENT AND CABLE OR
WIRE CONNECTIONS.
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IMPORTANT
ALL CONNECTIONS SHOULD BE MADE AFTER CAM-5 IS PANEL MOUNTED.
IMPORTANT
IT IS RECOMMENDED THAT FERRULES BE USED FOR ALL WIRE TERMINATIONS.
Figure 10: CAM-5 Connections and Common Wiring
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3.1 Power Connection

Connector included with purchase of unit
The CAM-5 HMI uses a single connector for AC/DC power. The connector is a 2-terminal male Euro Style
plug that accepts a mating 7.62mm pitch screw terminal adapter. The adapter accepts 16-26 AWG wire.
Power connections shall be a minimum 18 AWG, tin-coated, soft drawn copper per ASTM B8, Class B
stranding, 300V rated. Insulation shall be EP (ethylene propylene) or EPCP (ethylene propylene
chlorosulfonated polyethylene compound).
Line and Neutral are symmetric in the CAMTM-5 and DC power may be applied at either polarity. Line and
Neutral have differential mode filtering and clamping to PE stud and have common mode filtering and
isolation to the remainder of the unit.
WARNING
POWER CABLES SHALL NOT BE ROUTED IN COMPARTMENTS WITH CONDUCTORS
EXCEEDING 300VAC. FAILURE TO MAINTAIN THIS SPACING CAN RESULT IN ARC FLASH,
PROPERTY DAMAGE, PERSONAL INJURY, AND LOSS OF LIFE.
3.1.1Input Power Details

The CAM-5 has a universal input power rating of:
• 100 to 250VAC 50/60 Hz 20W

• 120 to 250DC1 20W
IMPORTANT
For best immunity to RF noise, the power cables should pass through a common ferrite and/or line
entry filter to improve measurements in high noise environments. Placing the ferrites immediately at
the conduit entry into the enclosure can reduce radiated EMI into the enclosure.
The following block diagram outlines the recommended power wiring for the CAM-5 with a 2-pole circuit
breaker for 120V AC input power.
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Figure 11: IntelliSAW CAM-5 Power Wiring
The following block diagram adds external AC line filters and surge arrestors for enhanced EMC
protection. Line filters will reduce conducted signals that may show as false positives for UHF partial
discharge measurements. The additional surge arrestors may be desired for 250Vac type 3 or 4
interfaces, as defined in IEC61000-6-5, or if EFT and surge voltages greater than 4KV or surges with
abnormally high occurrence are anticipated.
Figure 12: Power Wiring With Surge Suppression And Power Line Filtering
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3.1.2Protective Earth (PE) wiring

Protective Earth (PE) connection should always be installed between the CAM-5’s PE lug and the PE
connection in the low-voltage compartment. Note, the PE connection is both a safety and a radio-
frequency ground. Use low inductance, high amperage wire, ensuring the shortest distance.
Must be earth bonded with <10” (<25cm) of multi-stranded or braided copper conductor meeting local
earth ground requirements.
WARNING
THE PE CONNECTION SHALL BE SIZED AND CONNECTED IN ACCORDANCE WITH LOCAL
ELECTRICAL CODE.
PROFESSIONAL INSTALLER OR OEM IS RESPONSIBLE FOR ALL CODE AND SAFETY

REQUIREMENTS ASSOCIATED WITH POWER CONNECTIONS.
IMPORTANT
While PE wiring in accordance with local code will address safety, immunity to common mode radio
frequency interference requires a low inductance (short, multi-stranded) ground to an earth bonded
metal structure. For best results, each instrument in the enclosure should have an independent, multi-
stranded earth connection (< 25cm) to an enclosure wall or low inductance ground bar.
THE USE OF DAISY-CHAIN GROUNDS OR LONG GROUND STRAPS ARE NOT RECOMMENDED.
3.2 RS485 Communication (Device and SCADA)

The CAM-5 may have two RS485 ports:
• Device port (RS485): Modbus Master to communicate with Readers

• SCADA port (RS485): Modbus Device to communicate with external SCADA.
Connectors are included with purchase of system options.
WARNING
SCADA AND DEVICE CABLES SHALL NOT BE ROUTED IN COMPARTMENTS WITH
CONDUCTORS EXCEEDING 300VAC. FAILURE TO MAINTAIN THIS SPACING CAN RESULT IN
ARC FLASH, PROPERTY DAMAGE, PERSONAL INJURY, AND LOSS OF LIFE.
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3.2.1CAM-5 Connection to Readers

The IntelliSAW readers are connected to the CAM-5 through a standard, half-duplex RS485 serial
Modbus RTU configuration. This is a 3-wire bus, differential signals for data +/- and a common signal
return. The common signal is clamped to PE (±50V MOV) for safety and connects to the line driver
through a high resistance to prevent ground loops. The figure below shows the various elements of a
network in a switchgear substation.
Data shield should be connected to PE at a single location per segment, typically at the end closest to the
CAM-5 in each segment.
Redundant screw terminals are provided for ease of daisy chaining RS-485 where the CAMTM-5 is not the
last device on the wire. Where it is the last device, a ½ Watt 120 Ohm resistor should be placed between
one Data+ and Data- with the network connected to the other Data+ and Data- plus D-COM.
Figure 13: RS485 Data Communication Bus Topology
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3.2.2CAM-5 Connections to External SCADA

The CAM-5 SCADA interface is one of:
• An Ethernet port with 5kV isolation capable of auto-negotiating 10/100.

• An LC port for 100Base-FX multimode cable.
• (custom model numbers only) A standard, half-duplex RS485 serial Modbus RTU configuration.
This is a 3-wire bus, differential signals for data +/- and a common signal return.
All connected readers can be queried through the SCADA interface.
Figure 14: RS485 SCADA Communication
3.2.3RS485 Cabling
3.2.3.1Recommended Cabling
IntelliSAW recommends the use of shielded cable for the RS485 wiring, providing at least one twisted
pair, one single line, and a drain wire, although typical cable has two twisted pair. The twisted pair
provides DATA+/- signals to each reader while the single line would be for D-COM, providing a low-
impedance return for each reader. The common signal is optional; however, if there are common mode
differentials between devices, data loss can occur with a two-wire installation. Differential pair should be
a twisted telecom wire with 100Ω nominal impedance. End to end resistance of the pair should be less
than 10Ω.
3.2.3.2Bus cable shielding

The drain wire associated with the RS485 bus shielding foil should be connected to the protective earth at
the source end (the end of the line segment closest to the bus master, usually the CAM-5) with the
destination end left unconnected. This prevents ground loops and induced noise. Each segment of the
bus should be shield-terminated to the protective earth in the cabinet from which it originates.
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3.2.4Bus Termination
The RS485 bus needs to be terminated at each end with 120 Ω resistors when long stretches of cable are
used. This ensures that the bus has the correct impedance. In general, RS485 adapters and bus masters
provide the source impedance internally and should be located at one end of the bus.
If the bus length is less than 2% of the maximum (e.g. 20 meters at 9600 baud with a 1km maximum), the
termination resistor may be omitted, provided that the bus master has failsafe resistors to bias the passive
line state. The CAM-5 has fail-safe biasing but no termination.
3.2.5Bus data rate (baud rate) considerations

The RS485 bus data rate is dependent on the bus cable length. In industrial environments, slower data
communication rates are generally more reliable; IntelliSAW recommends 9600 baud for the data rate.
The protective circuitry used to meet IEC61000-6-5 places significant capacitance on the line and,
at data rates above 9600 baud, proportionately fewer devices are allowed on the line.
Bus length
Bus cable length has an impact on the overall data rates that can be achieved. A conservative rule for
RS485 uses the equation: (baud rate * cable length (m)) < 10 x 106. A 9600 baud network would require
a bus less than (10 x 106 ÷ 9600), or 1042 meters (about 3400 feet). This is perfectly adequate for most
substation installations.
3.3 Humidity Sensor Connections

The IntelliSAW Humidity sensors are shipped with a cable assembly.
The Humidity Sensor Connector is a 4-position male connector accepting 16-26 AWG wire. For more
details, reference the (910.00379.001) IntelliSAW Sensor Installation Manual.
WARNING
HUMIDITY CABLES MUST BE KEPT AWAY FROM ALL MEDIUM VOLTAGE CONDUCTORS AND
ANY LOW VOLTAGE CONDUCTORS EXCEEDING 300VAC.
THE SEPARATION REQUIRED FOR REINFORCED ISOLATION IS THE GREATER OF THE

VALUES REQUIRED BY IEC62271 “NO TEST” BIL SPACING AND THE DISTANCE REQUIRED BY
LOCAL CODE. FAILURE TO MAINTAIN THIS SPACING CAN RESULT IN ARC FLASH, PROPERTY
DAMAGE, PERSONAL INJURY, AND LOSS OF LIFE.
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3.4 Air Interface Connections

The IntelliSAW Air Interfaces are shipped with a cable assembly.
The CAM-5 supports up to 4 Air Interface connections (Port 1 to Port 4) through female SMA
connections. Only IntelliSAW provided Air Interfaces are suitable for the desired performance and for
compliance with transmitter authorizations. For more details, reference the (910.00379.001) IntelliSAW
Sensor Installation Manual.
WARNING
RF CABLES MUST BE KEPT AWAY FROM ALL MEDIUM VOLTAGE CONDUCTORS AND ANY
LOW VOLTAGE CONDUCTORS EXCEEDING 300VAC.
THE SEPARATION REQUIRED FOR REINFORCED ISOLATION IS THE GREATER OF THE

VALUES REQUIRED BY IEC62271 “NO TEST” BIL SPACINGS AND THE DISTANCE REQUIRED BY
LOCAL CODE. FAILURE TO MAINTAIN THIS SPACING CAN RESULT IN ARC FLASH, PROPERTY
DAMAGE, PERSONAL INJURY, AND LOSS OF LIFE.
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3.5 Alarm Wiring

Connector is shipped with system option
WARNING
ALARM CABLES SHALL NOT BE ROUTED IN COMPARTMENTS WITH CONDUCTORS
EXCEEDING 300VAC. FAILURE TO MAINTAIN THIS SPACING CAN RESULT IN ARC FLASH,
PROPERTY DAMAGE, PERSONAL INJURY, AND LOSS OF LIFE.
IMPORTANT
ALARM OUTPUTS ARE FOR INDICATION ONLY AND ARE NOT INTENDED FOR CONTROLLING
THE ELECTRICAL PROCESS.
Six (6) Form C Dry Contact Relays are provided with the Alarm option. A common signal is applied to A-
COM, and, at normal state, will be connected to the NC contact for each relay. When a relay closes on a
positive alarm trigger, the common signal will propagate through the NO contact after breaking the NC
connection.
Figure 15: Relay wiring with high side common.
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Figure 16: Relay wiring with low side common.
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3.6 Example Wiring Diagram

The example wiring diagram shows how a typical CAM-5 unit would be wired using Modbus RTU to
communicate to the SCADA system.
Figure 17: Example Wiring Diagram
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Section 4 HMI Overview

The CAM-5 provides a Human-Machine Interface (HMI) allowing operators to visualize data, trending, and
alarms. The CAM-5 accepts up to 10 IntelliSAW Readers through the multi-unit hardware option (Modbus
RTU); the CAM-5 internal monitoring would be considered one of the ten channels.
The following section provides details on the HMI views and operations.
4.1 Home Screen

The CAM-5 home screen provides a system measurement summary, alarming information, system
health, CAM-5 reboot, and a method to step into the details of each connected external data device. The
active devices will have available data based on their individual measurement configurations.
Figure 18: Example CAM-5 Home Screen
4.1.1Home Screen Segments

The Home screen is broken into many segments detailed below:
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4 5 6 7 8 9
1
5 5 5 5 5
Figure 19: Example CAM-5 Home Screen Segments
Segment Description
1 Date/Time. The date/time stamp is factory set as UTC+0
Device Select Buttons. The CAM-5 unit and extended data device
measurements can be cycled through by selecting the appropriate
2
button. The detail screens will loop 5 times and then return to the
home screen.
System Status. The CAM-5 status bar indicates:

- Status: system activity details will show in a text bar
- System display units
- System Indicators: Received data (Rx), dead-band trigger
(db), timer trigger (dt), and Alarms’ status
- Versions button: shows device versions
- Network button: shows device’s network cards’ settings
3
information
- Capture button: taking screen captures (saves to extended
memory)
- Reboot button: reboots the CAM-5 unit
- Date button: allows the setup of time and date, and shows
the time zone. The CAM Display Tool is needed to edit the
time zone.
Max Temperature (Max Ts). Shows the maximum temperature of
4
all sensors being interrogated by the measurement device.
5 Max Differential Temperature (Max dT). Show the maximum

temperature differential between groups of 3 sensors being
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interrogated by the measurement device. Groups are defined

based on unit configuration.
Max Relative Humidity (Max RH). Shows the maximum Surface

6 Discharge of all sensors being monitored by the measurement
device.
Max Surface Discharge (Max SD). Shows the maximum Surface

7 Discharge of all Air Interfaces configured for PD monitoring by the
measurement device.
Max Partial Discharge (Max PD). Shows the maximum Partial

8 Discharge of all Air Interfaces configured for PD monitoring by the
measurement device.
Alarms. There are 6 Alarm outputs associated with readings. Each

connected unit can trigger the alarm. The check box indicates if an
9 alarm is active for that unit. A glossary with the abbreviations for
the Warning/Alarms is shown on Section 4.1.2 HMI Warning &
Alarm Indications
4.1.2HMI Warning & Alarm Indications

Warnings and alarms can be triggered from absolute temperatures, the difference within a group of three
temperature sensors, relative humidity, or surface or internal partial discharge events.
When a warning occurs, the measurement which created the warning will turn yellow along with the alarm
indicator and associated status bar indicator. When the measurement results in an alarm all indicators
previously mentioned will turn red and the alarm relay will activate (if option is available). The example
shows a warning on Max SD and an alarm on Max dT.
Alarm States
• Yellow (warning) will show immediately

• Alarm (red) requires three consecutive readings over or under the configured limit to set / reset
the alarm status
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Figure 20: Example of Warning and Alarm Status
The following abbreviations show the active Warning or Alarm indicators on the Status Bar:
# Label Description # Label Description

0 -- Alarm Not Defined
1 Ta Temperature Alarm 13 αa SD Alpha Alarm
2 Tw Temperature Warning 14 αw SD Alpha Warning
3 Da Temperature Delta Alarm 15 αA PD Alpha Alarm
4 Dw Temperature Delta Warning 16 αW PD Alpha Warning
5 Aa Ambient Alarm 17 βa SD Beta Alarm
6 Aw Ambient Warning 18 βw SD Beta Warning
7 Ha Humidity Alarm 19 βA PD Beta Alarm
8 Hw Humidity Warning 20 βW PD Beta Warning
9 Sa SD Alarm 21 φa SD Phi Alarm
10 Sw SD Warning 22 φw SD Phi Warning
11 PA PD Alarm 23 φA PD Phi Alarm
12 PW PD Warning 24 φW PD Phi Warning

!!! Note: Capital “A” and “W” used for PD, lower case “a” and ”w” used for SD
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4.1.3Unit Details & Measurement Selection

Selecting the unit button (example in Figure 20 above: SEC 1-2) will step into the unit’s details and cycle
through the individual measurement pages.
Selecting the specific unit measurement will go directly to the unit’s detailed measurement page. For
example, on the home screen in the Figure 20 above, when selecting the Max Ts for the SEC 1-2
(46.1⁰C), the HMI will go to that device’s detail page as shown in the CAM-5 Example Device Detail
Screen (Figure 24).
4.1.4Versions
The versions button can be selected to evaluate the CAM5 Applications List and currently installed
versions. Select OK to exit screen.
Figure 21: CAM-5 Versions
4.1.5Network
After pressing the Network button on the Home Screen, the CAM5 Network Information dialog shows the
configuration information for each Ethernet Network Card including Activity State, IP Address, Subnet
Mask, Gateway, and MAC Address. “down” indicates that the interface is not connected to a network,
while “up” indicates a physical layer link is established.
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The setup of the network card configuration can be done in the CAM Display Tool.
Figure 22: CAM-5 Network Information
4.1.6Capture & Log Files

A USB device can be placed in the extended memory USB port on the back of the CAM-5 for logging
data and capturing screen shots. The memory stick must have a folder called logfiles to save data and
capture files.
4.1.7Reboot
On the Home Screen a Reboot button lets you cycle the power of the CAM-5 unit. After pressing it a
dialog will prompt if you are sure to reboot the terminal, and after pressing the Yes button it restarts, to
cancel tap No.
4.1.8Date
The Date button on the Home Screen allows modifying the current date and time settings. You may be
able to tap over the day, month, year, hour, or minute and increase or decrease its value with the Up or
Down Arrow. The Save button must be pressed for the new values to be written. The time zone may
only be set on the CAM Display Tool.
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Figure 23: CAM-5 Date and Time Configuration
4.2 Device Specific Detail Screens

Each connected device has its own specific detail screen which is configurable. The CAM-5 application
allows each screen to be enabled/disabled and for the text on each screen to be customized. The CAM-5
cycles through each enabled screen once every 5 seconds. The following display screens are available
and the Data and Graph views are configurable to be enabled (visible) or disabled.
Measurement Type Display Screens Data
Temperature Data & Graph Up to 12 sensors

Humidity / Ambient Temp Data & Graph Up to 8 sensors
Data All Summary PD & SD
Air Interface – port 1

Partial Discharge Summary Air Interface – port 2
Graphs
4.2.1Device Detail Screen Overview

Each device detail screen is slightly different depending on the data it’s displaying, but there are a few
main sections:
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5
1
Figure 24: CAM-5 Example Device Detail Screen
Section Description
1 Date/Time. The date/time stamp
2 Data Device Name. The specific device’s name the data is being displayed for.
Function Buttons.
Freeze: Stays on the current detail screen for 5 minutes.
Next: Moves to the next detail screen.
3 Home: Goes to the home screen.
Versions: Shows unit versions.
Network: Shows network cards’ configuration information.
Capture: Generates a screen capture.
System status. The CAM-5 system status bar includes:

- Text bar for details on an action that occurred.
4
- Indicators for received data (Rx), dead-band trigger (db), timer trigger (dt), and
Alarm status
Data Field. Depending on the data type and whether it is numerical or graphical, this
section will change.
Numerical data fields: white background indicates normal status. Yellow
5
background indicates warning level active, and red background alarm level active.
Graphical data: the graph timespan can be configured. The vertical axis auto-
scales with the measurements.
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4.2.2Temperature Measurements
4.2.2.1Numerical Data Screen
The data points are grouped in sets of three and dT is based on these groups. The data fields are fixed
groups based on the data device’s (Reader or CAM-5 internal) physical Modbus registers as shown in the
table below. The registers are configured using the IntelliSAW Configuration Tool. Only configured
registers which read with values other than error codes will show on the HMI. The HMI group text
headings are configurable.
Device Physical
Data Group
Modbus Register
1 418 – 420
2 421 – 423
3 424 – 426
4 427 – 429
Table 1: Modbus Registers for Temperature Measurements
Figure 25: Temperature Numerical Data Screen Example
4.2.2.1.1 Delta-T (dT)

The delta-T is the max value based on the temperature difference between the temperature sensors in an
associated group. Although dT is displayed and alarms can be triggered from this calculation, the value is
NOT stored in Modbus registers.
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4.2.2.2Graphical Data Screen

The temperature sensor data can also be displayed as a graphical trend. The legend shows all available
sensors (up to 12) and 1 ambient temperature sensor. The graph only displays data for enabled registers
in the Home Screen.
Figure 26: Temperature Graphical Display Example
Notes:
➢ Ambient Temperature is pulled from the first connected Humidity Sensor to a device
➢ Legend labels cannot be modified through the CAM Display Tool.
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4.2.3Humidity and Ambient Temperature

4.2.3.1Numerical Data Screen
CAM monitoring units support up to 8 humidity sensors – e.g. for bus duct monitoring between generators
and transformers. The ambient temperature, relative humidity, and dew point are displayed. The
ambient sensors are displayed sequentially based on their address (starting with address 0) when
configured with the CAM Display Tool. The text location names can be edited based on system
installations.
Figure 27: Ambient Temperature and Humidity Screen Example
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4.2.3.2Graphical Data
The ambient temperature / humidity sensor data can also be displayed in a graphical form. The legend
shows all available sensor data (up to 8).
Figure 28: Ambient Temperature and Humidity Graph Example
Notes:
➢ Legend labels cannot be modified through the CAM Display Tool.
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4.2.4Partial Discharge
IntelliSAW monitoring units include specific hardware and an algorithm for analyzing ultra-high frequency
(UHF) radio emissions to detect and quantify the signatures of symmetric and asymmetric discharges that
are synchronous with the power line frequency, while distinguishing them from other modulated UHF
emissions that come from non-discharge related noise sources. Monitoring units support up to 4 PD Air
interfaces (model: TPD). The IntelliSAW partial discharge detection solution specifically monitors three
distinct bands (300MHz, 600MHz, and 1200MHz) affording multiple opportunities to detect partial
discharge events and to distinguish these events from noise sources.
All raw frequency data is provided through Modbus registers and stored to local data storage – this data
does not get displayed on the HMI. The HMI can report the surface discharge (SD), partial discharge (PD)
parameters for each port connected to a suitable air interface.
4.2.4.1PD Monitoring Signals

The IntelliSAW system classifies the processed modulation signals into three categories: noise, partial
discharge (PD) and surface discharge (SD).
4.2.4.1.1 Noise
Noise denotes UHF energy in the selected frequency band(s) that does not correlate well with the power
line frequency. External radio interference is reliably classified as noise; however weak and erratic partial
discharge – which occurs early in the evolution of a defect – can sometimes also be classified as noise.
4.2.4.1.2 Partial Discharge (PD)

Partial discharges that occur in insulation surrounding conductors have a more symmetric pattern with
respect to the power line frequency. The portion of incoming energy matching this pattern is classified as
PD. The value represents the magnitude of the symmetric signal in excess of the combination of detected
noise and the asymmetric value.
4.2.4.1.2.1 Summary PD
Summary PD is the maximum PD for one antenna port accumulated in one register over the enabled
bands. The enabling / disabling of frequency bands will affect the summary value if the enabled or
disabled band is the highest. This data point in the Modbus registers should be used for trending.
4.2.4.1.2.2 Partial Discharge – Alpha (α)

PD-Alpha (PDα) is the short-term exponential weighted averaging PD for one antenna port accumulated
in one register over the enabled bands during a short period of time (a.k.a. Averaging Hours) – generally
24 hours, configurable by the CAM Display Tool. The enabling / disabling of frequency bands will affect
the summary value if the enabled or disabled band is the highest. This data point in the Modbus registers
may be used for trending.
4.2.4.1.2.3 Partial Discharge – Beta (β)

PD-Beta (PDβ) is the long-term exponential weighted averaging PD for one antenna port accumulated in
one register over the over the enabled bands during a long period of time (a.k.a. Baseline Hours) –
generally 7 days, configurable by the CAM Display Tool. The enabling / disabling of frequency bands will
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affect the summary value if the enabled or disabled band is the highest. This data point in the Modbus
registers may be used for trending.
4.2.4.1.2.4 Partial Discharge – Phi (φ)

PD-Phi (PDφ) is the PD change rate for one antenna port over the enabled bands. The enabling /
disabling of frequency bands will affect the summary value if the enabled or disabled band is the highest.
This function seeks to measure the normalized rate of increase of the PD activity. This data point in the
Modbus registers may be used for trending.
4.2.4.1.3 Surface Discharge (Corona)

Surface discharges are events that depend on the polarity of an object because of a metal/air boundary.
These events occur on the negative polarity wave cycle when emitted electrons ionize the air, causing
corona discharges. The value represents the magnitude of the asymmetric signal in excess of detected
noise.
4.2.4.1.3.1 Summary SD
Summary SD is the maximum SD for one antenna port accumulated in one register over the enabled
bands. The enabling / disabling of frequency bands will affect the summary if the enabled or disabled
band is the highest. This data point in the Modbus registers should be used for trending.
4.2.4.1.3.2 Surface Discharge – Alpha (α)

SD-Alpha (SDα) is the short-term exponential weighted averaging SD for one antenna port accumulated
in one register over the enabled bands during a short period of time (a.k.a. Averaging Hours) – generally
24 hours, configurable by the CAM Display Tool. The enabling / disabling of frequency bands will affect
the summary value if the enabled or disabled band is the highest. This data point in the Modbus registers
may be used for trending.
4.2.4.1.3.3 Partial Discharge – Beta (β)

SD-Beta (SDβ) is the long-term exponential weighted averaging SD for one antenna port accumulated in
one register over the over the enabled bands during a long period of time (a.k.a. Baseline Hours) –
generally 7 days, configurable by the CAM Display Tool. The enabling / disabling of frequency bands will
affect the summary value if the enabled or disabled band is the highest. This data point in the Modbus
registers may be used for trending.
4.2.4.1.3.4 Surface Discharge – Phi (φ)

SD-Phi (SDφ) is the SD change rate for one antenna port over the enabled bands. The enabling /
disabling of frequency bands will affect the summary value if the enabled or disabled band is the highest.
This function seeks to measure the normalized rate of increase of the SD activity. This data point in the
Modbus registers may be used for trending.
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4.2.4.2PD Monitoring Units

The IntelliSAW system measures the integrated (cumulative) discharge over a power cycle with a relative
scale approximately related to pico-coulombs (pC) cumulative / power cycle. The MODBUS registers are
scaled by 10 with counts of 1 – 65534 representing approximately 10 – 655,340 pC cumulative (but non-
linear and un-calibrated by default). The measured values depend on the distance of the air interface
from the discharge and may other factors. While the result can be calibrated to a reference location using
a discharge synthesizer, variability in the source of real discharges and the exact nature of the discharge
will have significant influences on the measurement, as does non-linearity in the detector. Therefore, the
resultant data from the unit should only be used for trending and differential analysis over time as an early
warning system for detecting corona and partial discharge and not as an absolute measurement.
4.2.4.3PD / SD Summary: Numerical Data Screen

The Numerical Data Screen shows the last measured PD and SD data for each Air Interface. Data will
only be shown for ports that have been configured to monitor PD or SD through the CAM Display Tool.
Figure 29: SD/PD Summary: Numerical Data Screen Example
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4.2.4.4PD / SD Summary: Graphical Data

The PD / SD data can also be displayed in a graphical form. There is a unique page for each port that
has been configured for PD monitoring. The data shows instantaneous values along with short and long-
term exponential weighted averages (α and β) for trending.
Figure 30: SD/PD Summary: Graphical Data Screen Example
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Section 5 HMI Configuration

The CAM-5 HMI configuration settings are stored in an XML file format and will need to be loaded onto
the unit.
Please refer to the (910.00384.0001) IntelliSAW CAM Display Tool User Manual for detailed
instructions on the CAM Display Tool and the process for loading a config.xml file onto a CAM-5 unit.
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Section 6 Measurement Configuration &

Sensor Installation
6.1 Measurement Configuration
If the CAM-5 has internal measurements (temp, PD, humidity), it will require measurement configuration
for the associated installed sensors. Configuration is performed through the USB mini port and uses the
IntelliSAW Configuration Tool. Details are not discussed here, please refer to the (910.00160.0001)
IntelliSAW Installation Tool User Manual for detailed instructions.
Figure 31: IntelliSAW Configuration Tool
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6.2 Sensor Installation

This manual does not cover specific sensor installation. Please reference the (910.00379.001)
IntelliSAW Sensor Installation Manual for more details.
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Section 7 SCADA System Integration

7.1 Modbus RTU or TCP
The CAM-5 connects multiple Readers through a master Modbus (RS485) connection. The SCADA
system connects to a CAM-5 through Modbus RTU (RS485) or Modbus TCP (Ethernet connection).
Either method will allow the SCADA system to query all connected Readers.
The following Modbus information is for CAM-5 Measurement Firmware rev.1335 or higher.
7.1.1MODBUS COMMANDS
The CAM-5 treats holding and input registers identically; however, HOLDING registers are the preferred
approach. Modbus-RTU payloads always begin with the address and a function code (FC). The CAM-5
supports the following Modbus function codes, as shown in the following table:
Command FC Description
2 Function code required by CiTect
MBF_READHOLDING 3 Fetch up to 81 of 256 defined registers
MBF_READINPUT 4 Exactly duplicates the MBF_READHOLDING command with the
same registers
MBF_PRESETSINGLE 6 Set a single register – do not use in reserved registers

MBF_DIAGNOSTICS 7 Sub-functions supported are 1, 4, 10-14
MBF_FETCH_CEC 11 Return 0x0000 if not busy, 0xFFFF if busy
MBF_PRESETMULTIPLE 16 Set up to registers
MBF_RESET_COMM 19 Reset CAM-5 HMI processor if successful.
MBF_RESET_COMM_ISR 7E <address> <7E> <AA> <55> <crc1> <crc2> resets CAM-5 HMI
XMS_XMESSAGE_FC 7F The remainder of the payload contains a native command.
Modbus-RTU payloads follow the MODICON standard except for special function codes, 7E and 7F. For
the 0x7F function code, the payload begins with address and 0x7F followed by an IntelliSAW native
protocol command payload.
The MBF_RESET_COMM_ISR command is a special sequence that reboots the processor from within
the serial receive interrupt service routine, regardless of protocol, when it is detected from a serial line idle
condition.
The MBF_RESET_COMM_ISR command must be properly formatted and successfully parsed. This
special sequence offers a means of resetting a CAM-5 HMI that is otherwise externally unresponsive.
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7.1.2MODBUS REGISTERS
Register Description Type Min Max Scale Error Code
4185 temp 1 signed 16 -500 1675 0.1 C 0x8000
419 temp 2 signed 16 -500 1675 0.1 C 0x8000
420 temp 3 signed 16 -500 1675 0.1 C 0x8000
421 temp 4 signed 16 -500 1675 0.1 C 0x8000
422 temp 5 signed 16 -500 1675 0.1 C 0x8000
423 temp 6 signed 16 -500 1675 0.1 C 0x8000
424 temp 7 signed 16 -500 1675 0.1 C 0x8000
425 temp 8 signed 16 -500 1675 0.1 C 0x8000
426 temp 9 signed 16 -500 1675 0.1 C 0x8000
427 temp 10 signed 16 -500 1675 0.1 C 0x8000
428 temp 11 signed 16 -500 1675 0.1 C 0x8000
429 temp 12 signed 16 -500 1675 0.1 C 0x8000
430 ambient 1 signed 16 -400 1250 0.1 C 0x8000
431 RH 1 unsigned 166 0 1000 0.1% RH 0xFFFF
446 SD1 Total unsigned 16 0 65534 10 "pC"7 0xFFFF
447 SD2 Total unsigned 16 0 65534 10 "pC" 0xFFFF
450 PD1 Total unsigned 16 0 65534 10 "pC" 0xFFFF
454 Data version = 1 unsigned 16 0 65534 na 0xFFFF
455 noise 1 unsigned 16 0 65534 10 "pC" 0xFFFF
5
Registers start at 0. 418 is 400418 or 0x01A2 in the datagram.
6 RH may be treated as signed 16 making the error code translate to a small negative number.
7 Partial discharge and surface discharge are nonlinear, and the scale is approximate.
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456 surface 1 unsigned 16 0 65534 10 "pC" 0xFFFF

457 internal 1 unsigned 16 0 65534 10 "pC" 0xFFFF
491 SD1 Num unsigned 16 0 65534 counts 0xFFFF
495 PD1 Num unsigned 16 0 65534 counts 0xFFFF
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499 Alpha SD 1 unsigned 16 0 65534 10 "pC"8 0xFFFF

500 Alpha SD 2 unsigned 16 0 65534 10 "pC" 0xFFFF
503 Alpha PD 1 unsigned 16 0 65534 10 "pC" 0xFFFF
507 Beta SD 1 unsigned 16 0 65534 10 "pC"9 0xFFFF
508 Beta SD 2 unsigned 16 0 65534 10 "pC" 0xFFFF
511 Beta PD 1 unsigned 16 0 65534 10 "pC" 0xFFFF
515 Phi SD 1 unsigned 16 0 65534 10 "pC"10 0xFFFF
516 Phi SD 2 unsigned 16 0 65534 10 "pC" 0xFFFF
519 Phi PD 1 unsigned 16 0 65534 10 "pC" 0xFFFF
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7.2 DNP3
Up to 10 readers can be bussed together via RS485 to a CAM-5 for displaying and datalogging; this is 9
units if the CAM-5 is also being used for monitoring. The CAM-5 supports DNP3 communications (serial
or TCP) and will connect to the SCADA system.
Figure 32: Block Diagram of a System Architecture
The total number of DNP3 data depends on the number of slaves configured. If for example only 2 slaves
are configured than total number of DNP3 Analog Values will be 164.
In DNP3 the data is sent as Analog Input Data starting from Index 0. If we have 8 Slaves configured the
following indexes will have the mapped ID of the MODBUS Device provided in the XML file. Followed by
81 register values.
Analog Input Mapped ID

Point Index
0 1
82 2
164 3
246 4
328 5
410 6
492 7
574 8
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7.2.1DNP3 flags
The following flags are set or reset based on the values and Modbus communications.
Restart: When CAM-5 is restarted the Restart Flag is set to All the points
Communication Lost: Is set when the CAM-5 loses communications to the slave device.
Local Forced: Set when communication is lost and values are forced in CAM-5 to Error Values.
Remote Forced: Set when communication is OK but the values received in CAM-5 are Error Values.
Over Range: Set for error values and also when value exceeds the limits.
7.2.2DNP3 Settings
Please reference the [910.00384.0001] IntelliSAW CAM Display Tool User Manual for more details.
Settings such as Station ID, Master ID, Analog Event Variation, Analog Static Variation, Class,
Unsolicited Mode and Timeout are commented in the document.
7.2.3DNP3 TLS and Secure Authentication

In TCP/IP mode Authentication and Transport Layer Security are supported.
7.3 IEC 61850

7.3.1Logical Nodes List
The following table contains the list of logical nodes implemented in the CAM-5:
G: Logical Nodes for generic references
GGIO (Generic process I/O)
L: System logical nodes
LLN0 (Logical Node Zero)
LPHD (Physical Device Information)
S: Logical Nodes for supervision and monitoring
SPDC (Monitoring and diagnostics for partial discharge)
T: Logical Nodes for instrument transformer and sensors
THUM (Humidity)
TTMP (Temperature sensor)
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7.3.2Mapping of Modbus to IEC61850

Register Description IEC61850 Mapping
N/A Mapped ID of the Modbus Reader CAM5_RdrNN/DevGGIO01$ST$IntIn1$stVal
418 temp 1 CAM5_RdrNN/TmpTTMP01$MX$TmpSv$instMag$f
430 ambient 1 CAM5_RdrNN/AmbTTMP01$MX$TmpSv$instMag$f
431 RH 1 CAM5_RdrNN/HumTHUM01$MX$HumSv$instMag$f
446 Total SD 1 CAM5_RdrNN/SdcSPDC01$MX$UhfPaDsch$mag$f
450 Total PD 1 CAM5_RdrNN/PdcSPDC01$MX$UhfPaDsch$mag$f
454 Data Version N/A
455 noise 1 N/A
456 surface 1 N/A
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457 internal 1 N/A

458 noise 2 N/A
459 surface 2 N/A
460 internal 2 N/A
461 noise 3 N/A
462 surface 3 N/A
463 internal 3 N/A
464 noise 4 N/A
465 surface 4 N/A
466 internal 4 N/A
467 noise 5 N/A
468 surface 5 N/A
469 internal 5 N/A
470 noise 6 N/A
471 surface 6 N/A
472 internal 6 N/A
473 noise 7 N/A
474 surface 7 N/A
475 internal 7 N/A
476 noise 8 N/A
477 surface 8 N/A
478 internal 8 N/A
479 noise 9 N/A
480 surface 9 N/A
481 internal 9 N/A
482 noise 10 N/A
483 surface 10 N/A
484 internal 10 N/A
485 noise 11 N/A
486 surface 11 N/A
487 internal 11 N/A
488 noise 12 N/A
489 surface 12 N/A
490 internal 12 N/A
491 Num SD 1 N/A
492 Num SD 2 N/A
493 Num SD 3 N/A
494 Num SD 4 N/A
495 Num PD 1 N/A
496 Num PD 2 N/A
497 Num PD 3 N/A
498 Num PD 4 N/A
499 Alpha SD 1 CAM5_RdrNN/SdaSPDC01$MX$UhfPaDsch$mag$f
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503 Alpha PD 1 CAM5_RdrNN/PdaSPDC01$MX$UhfPaDsch$mag$f
507 Beta SD 1 CAM5_RdrNN/SdbSPDC01$MX$UhfPaDsch$mag$f
511 Beta PD 1 CAM5_RdrNN/PdbSPDC01$MX$UhfPaDsch$mag$f
515 Phi SD 1 CAM5_RdrNN/SdpSPDC01$MX$UhfPaDsch$mag$f
519 Phi PD 1 CAM5_RdrNN/PdpSPDC01$MX$UhfPaDsch$mag$f
NN = 01 to 10 Readers
7.3.3Mapping of Digital Output to IEC61850

Relay No IEC61850 Mapping
1 CAM5_Dop/StsGGIO01$ST$Alm1$stVal
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Section 8 Specifications
Temperature
Operating Frequency 425 to 443 MHz
SAW Sensors 0 to 12
Redundancy Model Up to 4 air interfaces
RF Transmit Power Pulsed, -6 to + 10 dBm (compliance mode dependent)
RF Receive Sensitivity -86 dBm
RF Receive Frequency Stability ± 700 Hz
RF Interrogation Distance Up to 1.75 m
RF Interrogation Time ≤ 160 mSec
Partial Discharge
Number of Channels 4
Sensor Type IntelliSAW TPD CAM Air Interfaces
Measurement Method Band-pass Ultra-High Frequency (UHF)
• 300MHz (270 – 330 MHz)

Measurement Bands • 600MHz (550 – 650 MHz)
• 1200MHz (1050 – 1400 MHz)
• Noise Floor
Measurement Types • SD – Surface Discharge (Tracking, Treeing, Corona, etc.)
• PD – Internal / Partial Discharge
Measurement Units QUHF

Measurement Scale Nonlinear, capability of normalizing to reference source
Sensitivity 100pC Qpk demonstrated in 24kV switchgear. Installation dependent.
Response Time 200 mSec
• Max SD
Calculated Data • Max PD
Calculated based on Signal to Noise Ratio (SNR)
• Fast averaging function (α)

Trending Algorithms • Long averaging function (β) – used as baseline
• PD acceleration trend function (Φ)
Humidity / Ambient Temperature

Number of Channels Up to 8
Sensor Types IntelliSAW IH-10 sensors
Measurement Types Relative Humidity, Ambient Temperature
Response Time 500 mSec
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Alarm Output Channels

Contact Type Dry Contact, Form C relays
Number of Channels 6 outputs (shared common)
Rated Voltage 250 V AC/DC
Continuous Withstand Capacity 10A
Make and Carry for 4s 15A
Breaking Capacity (AC) 2500VA
Breaking Capacity (DC) 24V, 5A / 125V, 0.45A DC
Contact Material AgNi 90/10
Mechanical Operations (40°C)
Full Load 30 X 103
No Load > 30 X 106
Open Contact Dielectric Strength 1000VRMS; 5000V contacts to coil isolation
Communication Interfaces
RS485 (Device)
Port 2-Wire (half-duplex)
Data Bus Baud Rate 1200 to 38400 baud
Data Protocol Modbus RTU Master
Response Time 500 ms
Supported Devices IntelliSAW IRM readers (up to 10 devices; baud rate dependent)
Optional RS485 (SCADA)
Port 2-Wire (half-duplex)
Data Bus Baud Rate 1200 to 38400 baud
• Modbus RTU Device

Data Protocols
• DNP 3 Outstation
Response Time 500 ms
Ethernet (ETH-1 & Optional ETH-2)
Port 10/100 BASE-T copper (RJ45 connector)

• Modbus TCP Client
• Modbus TCP Server
• Modbus data push to Server11
Data Protocols • DNP3 Outstation
• IEC 61850
• sftp, ssh
• email notifications
11A low data usage method of pushing data to a remote server from multiple, distributed clients.
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Optional Ethernet (ETH-2 FIBER)
Port 100 BASE-FX of IEEE802.3u
Wavelength 1300 nm
Optical Connector LC duplex connector
Type Multimode
Fiber Size 62.5/125 μm
Min: -19 dBm avg

Output (TX) Power Typical: -15.7 dBm avg
Max: -14 dBm avg
Min: -30 dBm avg

Receive (RX) Sensitivity
Max: -31 dBm avg
• Modbus TCP Client

• Modbus TCP Server
• Modbus data push to Server12
Data Protocols • DNP3 Outstation
• IEC 61850
• sftp, ssh
• email notifications
Measurement Configuration (CNFG)
Port USB 2.0 Mini-B; Windows COM port with FTDI drivers, 115200 baud.
Data Protocols IntelliSAW Native Protocol
Protection Type 1 (protected area); light industrial protection, configuration only
Extended Memory (USB)
Port USB 2.0 Type A host
Use Extended Memory – Required for Trending
Data Storage CSV file format extension
Protection Type 1 (protected area); light industrial protection, configuration only
Factory only.
Micro SD
Type 1 (protected area); light industrial protection, configuration only
12 A low data usage method of pushing data to a remote server from multiple, distributed clients.
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Operating Power
AC input 100 to 250V AC 50 / 60 Hz
DC input 120 to 250V DC (functional, no FCC or UL tests)
Power Consumption 20W
Physical / Environmental
HMI Resistive Touch Panel (5” / 800 x 480 resolution)
Body: 143.6 mm W x 100.25 mm H x 101.6 mm D

Dimensions:
Panel: 153.4 mm W x 110.2 mm H x 3.14 mm D
Weight
Typical: 0.98 kg (2.16 lbs)
Will vary with model
Mounting Style Panel Mount, Cutout: 144.9 mm W x 101.65 mm H
Operating Environment
Pollution Degree 2
Overvoltage Category Cat III Mains < 300V
International Protection (IEC 60529) Panel (IP 62), Body (IP 20)
-20°C to +70°C
Temperature
+55°C @ 250VAC
Max altitude: 5000 m

Indoor Use
Max humidity: 95% RH
Environmental Testing
Environment testing (IEC-60721-3-3) for High Voltage Switchgear and Control Gear (IEC-62271) – Category C1
Cold Test
IEC 60068-2-1
-25C for 16 hours minimum
Dry Heat
IEC 60068-2-2
+ 75C for 16 hours minimum
Damp Heat
IEC 60068-2-3
+38C 95% RH for four days.
Vibration
Class 1 Test is based on the IEC-60225-21-1
IEC 60255-21-1
Powered 0.035mm 10Hz to 60Hz, 0.5g 60 to 150Hz
Unpowered 1g 10 to 150Hz
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Section 9 Product Certifications

9.1 Compliance Testing
FCC Part 15
Radiated Emissions
Radiated Emissions FCC Part 15.231, ANSI C63.4, and IEC
61000-6-4 Class A13.
AC Mains Conducted Emissions

Conducted Emissions (FCC Part 15 Subpart B: 09/2017, FCC 15.231: 09/2017,
IEC 61000-6-4: 02/2011)
UL / cUL / IEC 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control, and
Registered Laboratory Use - Part 1
Cat III MAINS < 300V to 5000m altitude (Unless otherwise specified)
Immunity for Power Station and Substation Environments

IEC61000-6-5
Type 4 (All ports, unless otherwise specified)
ESD immunity
Severity Level:
IEC 61000-4-2
• Front (LCD): ±8kV contact & ±15kV air discharge (level 4)
• Back (Connectors): ±6kV contact & ±8kV air discharge (level 3)
Radiated Field Immunity (rEMI)

IEC 61000-4-3
Severity Level: 10V/m (class A) 30V/m (class B)
Electrical Fast Transient immunity (EFT)

IEC 61000-4-4
Severity Level: 4kV
Surge Immunity
Severity Level:
IEC 61000-4-5 • 250VAC: ±2kV line-line (A), ±4kV line-Earth
• 120VAC: ±2kV line-line (A), ±4kV line-Earth (A)
• IO modules: ±4kV line-Earth (A)
CRFI - Immunity to conducted RF disturbances

IEC 61000-4-6
Severity Level: 10Vrms (class A)
13 Radiated emissions other than the wireless sensor interrogation is independent of enclosure. Fixed
site EMC compliance under IEC 61000-6-4 requires typically 50dB of shielding from the metal enclosure
and associated facility infrastructure, with TPD antennas at full power. Reduced shielding may be
allowed with less efficient antennas or by reducing the TX power limits.
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Power frequency magnetic field immunity

IEC 61000-4-8
Relevant modules: 100A/m cont. 1kA/m 1s. (class A)
Voltage dips and interrupts

input current not exceeding 16 A
IEC 61000-4-11
• 70%/1 cycle Pass (class A)
• 40%/50 cycles Pass (class A)
Immunity to conducted, common mode 0 to 150 kHz

• 300 Vrms 1 second (class A)
IEC 61000-4-16
• 30 Vrms Continuous (class A)
• Level 3 Sweep (class A)
Damped oscillatory wave immunity

IEC 61000-4-18 • Slow wave 1MHz 2.5kV (class A)
• Fast Wave 10MHz 1.0kV (class A)
9.2 Wireless Certifications

9.2.1Telecommunication Compliance
All wireless devices require certification to ensure that they adhere to regulations regarding the use of the
RF spectrum. Nearly every country requires this type of product certification. IntelliSAW is working with
governmental agencies around the world to supply fully compliant products and remove the risk of
violating country directives or laws governing wireless device usage. However, certification is ultimately
dependent on the class of asset into which the equipment is installed. In the US and Canada, FCC and
IC have given formal approval for use in metal enclosed switchgear. In most of Europe, Asia, Middle
East, and Africa, the rules are similar to the EU EMC Directive.
9.2.2Approved Antennas
The CAM-5 RF module has been approved to operate with the Air Interface (antenna) types listed below
with the maximum permissible gain indicated. Air Interface types not included in this list, having a gain
greater than the maximum gain indicated for that type, are strictly prohibited for use with this device under
FCC or IC approvals.
IntelliSAW Part # Type Gain

IA-MM-5-y Monopole (5 cm mast) -1 dBi
IA-MM-9-y Monopole (9 cm mast) +1 dBi
IA-MM-17-y Monopole (17 cm mast) +3.2 dBi
IA-MM-TPD-y Patch inverted F (PIFA) +3.5 dBi
IA-MM-TMP-y Patch inverted F (PIFA) +3.5 dBi
Part Number (“y”) indicates cable lengths
Note: Air Interface’s highlighted in blue are discontinued for sale but are still supported.
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9.2.3Federal Communications Commission (FCC)

This product contains FCCID: 2AEAE-ISAW-RF-H0215
The design of the CAM-5 complies with U.S. Federal Communications Commission (FCC) guidelines
respecting safety levels of radio frequency (RF) exposure for fixed location devices.
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant
to part 15 of the FCC Rules when the unit is professional installed in metal enclosures described in the
IEEE standard C37.20. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio communications. Operation of this equipment
in a residential area is likely to cause harmful interference in which case the user will be required to
correct the interference at his own expense.
9.2.3.1Installation Requirements
The IntelliSAW CAM-5 and approved Air Interfaces can be professionally installed in the following
installation environments:
1. Metal enclosures described in the IEEE/ANSI Std C37.20, or UL and NEMA specifications
derived from Std C37.20, as indicated in KDB 550099.
a. The CAM-5 HMI is not required to be in such an enclosure since the Air Interface is wired
away from the host.
b. The CAM-5 HMI firmware shall be configured for ANSI
2. Open air operation
a. The Air Interface and CAM-5 can operate outside of the metal enclosures when the CAM-
5 firmware is configured for Open Air operation.
Changes or modification to the equipment not expressly approved by IntelliSAW could void the
user's authority to operate the equipment.
9.2.4Industry Canada (IC)

This product contains device certified under IC: 11526A-ISAWRFH0215
This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the
following conditions:
• This device may not cause harmful interference.

• This device must accept any interference received, including interference that may cause
undesired operation.
Changes or modification to the equipment not expressly approved by IntelliSAW could void the user's
authority to operate the equipment
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Ce produit contient un appareil certifié en vertu IC: 11526A - ISAWRFH0215
Cet appareil se mets en conformité avec les normes CNR d’Industrie Canada applicables aux appareils
radio exempts de licence. L’exploitation est autorisée aux conditions suivantes:
• L’appareil ne produit pas de brouillage malfaisant.

• L’appareil doit accepter tout brouillage radioélectrique reçu, y compris le brouillage qui pourrait
provoquer le fonctionnement non désiré.
Les changements ou les modifications apportés à l'équipement qui n'est pas expressément approuvé par
IntelliSAW pourraient annuler l'autorité de l'utilisateur à utiliser cet équipement.
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Contact
Head Office
IntelliSAW – ALTANOVA GROUP
Rosemount Inc.
100 Burtt Road, Suite 201
Andover, MA 01810
contact@intellisaw.com
+1-978-409-1534
www.altanova-group.com
Regional Distributors:
Visit www.altanova-group.com for sales channel partners.
The contents of this publication are presented for information purposes only, and while effort
has been made to ensure their accuracy, they are not to be construed as warranties or
guarantees, express or implied, regarding the products or services describe herein or their
use or applicability. All sales are governed by our terms and conditions, which are available
on request. We reserve the right to modify or improve the designs or specifications of our
products an any time without notice.
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User Manual

3.2.3 RS485 Cabling ........................................................................................................................ 28

Section 8 Specifications .......................................................................................................................... 62

This symbol identifies messages in this document related to safety.

This manual covers CAM-5 functionality, configuration, safety, and installation.

Model Number Description

1.2 Instructions for Use

1.3 System Inputs and Outputs

Figure 1: Example CAM-5 back label

1.4.2Serial Number, Safety and Compliance Label

Figure 2: CAM-5 Safety and Compliance Label

Failure to follow these instructions can result in personal injury.

Figure 3: CAM-5 Dimensions (in mm)

• (1) Input Power Connector

• (4) SMA (RF) connectors – used for air interface connections

Ethernet (system) USB-Mini-B USB-Standard-A

Alarms Ground Lug

Figure 4: CAM-5 Back View SCADA

• No Illumination: No Power to RF measurement card

Figure 6: CAM-5: Right Side View

Line / (+) Line 1, DC+ Input power range:

Neutral / (-) Neutral, Line 2, DC- 2-Phase AC uses (N / -) as Line 2

2.3.2Chassis Ground Connector – Protective Earth

Chassis ground / protective earth lug connection, required for

2.3.4USB Mini-B Cable Connector

Mini-B CNFG USB Mini-B used for unit configuration

2.3.5USB Standard-A Connector

2.3.6SD Micro Connector

2.3.7.1Modbus RTU Connector

Pin Name Description

2.3.9SMA (RF) Connectors

2.3.10 Humidity Sensor Connector

2.3.11 Relay Alarm Connector

2.4 Panel Mounting

ENSURE THE INSIDE OF THE PANEL IS WITHIN THE CAM-5 OPERATING

2.4.3Mounting Bracket Installation

Figure 7: CAM-5 lower two mounting clips.

Figure 8: CAM-5 lower left and right mounting clips.

Figure 9: CAM-5 mounted with PE wire to earthed panel.

PROFESSIONAL INSTALLER OR OEM IS RESPONSIBLE FOR ALL CODE AND SAFETY

Figure 10: CAM-5 Connections and Common Wiring

3.1 Power Connection

3.1.1Input Power Details

• 100 to 250VAC 50/60 Hz 20W

Figure 11: IntelliSAW CAM-5 Power Wiring

3.1.2Protective Earth (PE) wiring

PROFESSIONAL INSTALLER OR OEM IS RESPONSIBLE FOR ALL CODE AND SAFETY

3.2 RS485 Communication (Device and SCADA)

• Device port (RS485): Modbus Master to communicate with Readers

Connectors are included with purchase of system options.

3.2.1CAM-5 Connection to Readers

Figure 13: RS485 Data Communication Bus Topology

3.2.2CAM-5 Connections to External SCADA

• An Ethernet port with 5kV isolation capable of auto-negotiating 10/100.

All connected readers can be queried through the SCADA interface.

Figure 14: RS485 SCADA Communication

3.2.3.2Bus cable shielding

3.2.5Bus data rate (baud rate) considerations

3.3 Humidity Sensor Connections

THE SEPARATION REQUIRED FOR REINFORCED ISOLATION IS THE GREATER OF THE

3.4 Air Interface Connections

THE SEPARATION REQUIRED FOR REINFORCED ISOLATION IS THE GREATER OF THE

3.5 Alarm Wiring

Figure 15: Relay wiring with high side common.