GaugeEmulator WM550 TRL2 BPM I and C Manual

Gauge Emulator
Installation and Commissioning

Contents
1 Overview 1
1.1 Introduction to the Gauge Emulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Installation 2
2.1 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Mechanical layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Mains Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 RS-485 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 BPM module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6 TRL/2 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7 Current Loop module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Configuration 13
3.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.1 Web browser configuration using the Ethernet port . . . . . . . . . . . . . . . . . . . . 14
3.1.2 SD card configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4 RS232 port 32
4.1 RS232 port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5 Operation 33
5.1 Power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 Searching for gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3 Polling for data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Troubleshooting 34
6.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7 Maintenance 35
7.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8 Appendix 36
8.1 GPU Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2 TRL/2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.3 WM550 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.4 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Release Notes
Product Version : 1.0.0

Document Version : 1.2.0
Master Port : Modbus E+H 8x gauge
Slave port : Honeywell Enraf GPU over BPM

: Emerson TRL/2
: Whessoe WM550 Current Loop
Operation : One to one
Document produced : October 31, 2018

Legal
Copyright Notice
This material contains information of proprietary interest to MHT Technology Ltd. It has been supplied in
confidence and the recipient, by accepting this material, agrees that the subject matter will not be copied
or reproduced, in whole or in part, nor its contents revealed in any manner or to any person except to meet
the purposes for which it was delivered.
Disclaimer
The information in this document has been checked and is believed to be entirely reliable, however no
responsibility is assumed for inaccuracies. MHT Technology Ltd reserves the right to make changes and/or
improvements in both the product and the product documentation without notice. MHT Technology Ltd
does not assume any liability arising out of the application or use of any product described herein; neither
does it convey any license under its patent rights or the rights of others.
Safety
This manual is directed to qualified personnel only in compliance with the national laws, including the
relevant rules. Routine and extraordinary maintenance operations will be carried out exclusively by
qualified operators with the supervision of expert personnel.
The hardware and software have not been designed to operate as a Safety Critical system. It is provided as
a means of monitoring only and should NOT be used as a safety system or part thereof.
The hardware and software must be used alongside a proven independent safety system.
Although the hardware and software may be part of a Tank inventory system providing a number of
indications to warn of current or impending situations regarding site conditions, or the health of devices,
appropriate independent means must be provided to verify and validate the integrity of measurements
and dynamic data at regular intervals.
CHAPTER 1
Overview
1.1 Introduction to the Gauge Emulator

The Gauge Emulator is a serial data protocol converter. It has been designed to integrate gauges of one type
into a fieldbus of a different type, such that the combination of the gauge(s) and Gauge Emulator appear to be
a gauge type appropriate to the fieldbus.
The Gauge Emulator firmware is stored in on-board memory, therefore allowing upgrade where new features
are required. Configuration of the gauge must be done using the tools appropriate to the gauge, configuration
of the gauge cannot be done through the Gauge Emulator.
It is assumed that the reader is already familiar with the operation of the gauge(s) and configuring the gauges(s)
which will connect to the Gauge Emulator. Guidance is provided herein as to those options and settings which
relate to the configuration and operation of the gauge with the Gauge Emulator.
It is further assumed that the reader is familiar with the operation and configuration of the system and fieldbus
which the Gauge Emulator is connecting to. Although some guidance is provided to assist in configuring the
Gauge Emulator and installing it into a system, the details provided are by no means exhaustive and are not
intended to cover every possible situation that may be encountered with a live system.
It is also assumed that the reader has an understanding of engineering terminology, such as binary code, Hex-
adecimal etc which is knowledge required in various setup procedures for the Gauge Emulator.
This manual needs to be read in full before installation and commissioning of the Gauge Emulator.
! This equipment must be installed, commissioned and operated in accordance with this and other
MHT product manuals. Using the equipment in any manner not detailed in the documentation is not
authorised and may impair electrical and explosive atmosphere protective features built into the equip-
ment.
Copyright ©2017 M.H.T Technology Ltd Page 1/42

CHAPTER 2
Installation
2.1 Mechanical Installation

The Gauge Emulator is housed in a cast aluminium alloy flameproof enclosure with a screwed lid. This enclosure
is approved for use in Zone 1 Hazardous Areas, Group IIC, Temperature Class T6. Ambient temperature range
-20 deg C to +55 deg C. Lower ambient temperatures are available as an option, consult certification plate on
enclosure for actual allowed ambient temperature range.
Although the orientation of the enclosure is not critical, best results will be obtained if the enclosure is bolted
to a vertical surface with the cable gland entries at the bottom.
Fixing holes are suitable for M10 or M12 bolts.
Figure 2.1: Enclosure

! The drilling of additional holes in the enclosure or modification of any of the existing threaded cable
entries will invalidate the Hazardous Area Approval of the Gauge Emulator. If the Gauge Emulator is to
be used in a Hazardous Area, no modifications to the enclosure are permitted.
! Cable glands must be installed in accordance with manufacturer’s instructions. A sealing washer
should be fitted between the gland and the enclosure or other approved sealing method be used to
provide protection against the ingress of water.
! When the Gauge Emulator is used in a Hazardous Area, all cable glands, adapters and stopping /
blanking plugs used must be certified and marked Ex ‘d’ IIC.
! Any unused holes should be blanked off accordingly.

2.2 Mechanical layout
The Gauge Emulator electronics, connectors and indicators are shown in the drawing below.
Figure 2.2: Mechanical layout
Port 1:- Master port, Nxx8x Modbus RS485 gauge.

Port 2:- Slave port, Field bus such as Honeywell BPM. Emerson TRL/2. Whessoe WM550 Current loop.
Port 3:- Whessoe WM550 Current loop.

2.3 Mains Electrical Installation
The Gauge Emulator requires connection to a mains power supply with the following characteristics :
100 ... 240 Vac.
50 ... 60 Hz.
15W / 0.375 A max.
The electrical ‘mains’ supply to the Gauge Emulator should be installed into the leftmost threaded entry in the
enclosure. The cable type selected must be suitable and appropriate for the intended environment and Haz-
ardous Area Zone classification in which the Gauge Emulator is installed, and through which the cable passes.
This will typically be an armoured cable and must be installed and glanded in accordance with applicable local
and national electrical regulations.
The ‘mains’ supply input terminals in the Gauge Emulator are adjacent to the leftmost threaded entry. They are
provided with a screw terminal socket that will accept wires up to 2.5 mm2 section and is removable to assist
access for termination.
Figure 2.3: Mains input terminals
The supply line (phase) and neutral should be connected to the terminals marked thus. Where the ‘earth’ pro-
tective conductor is provided as a third core in the cable, this should be connected to the PE terminal of the
connector. Alternatively, an M6 earth screw is provided to the left of the chassis that may be used to connect
‘earth’ / protective conductors that are too large to be accommodated in the input connector. Use M6 ring crimp
terminations. Ensure that the ‘earth’ terminal is fully tightened.
The Gauge Emulator is a Protection Class I device, and must be earthed at all times, in addition to any equipo-
tential bonding requirements of the Hazardous Area installation. An external earth bonding point is provided
at the bottom of the enclosure to which supplementary bonding conductors and / or cable gland earthing tails
may be connected.

A suitable switch or circuit breaker must be provided in the ‘mains’ supply to the Gauge Emulator as a means
of disconnection from the supply source, fulfilling the requirements of IEC 60974-3 (load switch with isolating
function). This shall disconnect all poles of the supply (L / N). The protective (earth) conductor of the supply
must not be switched / interrupted by the disconnecting device, and must remain connected at all times for
electrical safety of the Gauge Emulator.
The Gauge Emulator may share the same ‘mains’ supply, and hence disconnection device, as the gauge to which
the Gauge Emulator is associated and connected. It must be labelled or marked as to its function as the discon-
nection device for the Gauge Emulator.
If not located adjacent to the position in which the Gauge Emulator is installed, so as to be readily accessible and
visible at that location, the disconnection device must be provided with a means for locking-off so as to prevent
inadvertent energisation of the supply to the Gauge Emulator whilst servicing activities are being carried out.
! Modification of any of the component parts of the Gauge Emulator or the inclusion of additional
equipment within the enclosure will invalidate the Hazardous Area Approval of the Gauge Emulator.
If the Gauge Emulator is to be used in a Hazardous Area, no modifications or additions to the Gauge
Emulator are permitted.

2.4 RS-485 module
RS-485 signals should be connected to the terminal block through a twisted pair, triple or two pair screened
and steel wire armoured instrumentation cable or equivalent when fitted in an ATEX enclosure and used in a
hazardous area or cable suited to the environment should be used. The terminal block on the RS-485 interface
module will accept wires up to 2.5 mm2 and may be unplugged from the board to assist wiring.
The RS-485 terminals and associated interface circuit are intended to operate at voltages not exceeding 12 V
relative to ‘earth’ ground potential.
The interface includes galvanic isolation of 1 kV DC between the internal and external circuits.
The “A” and “B” lines must always be connected for RS-485. The “A” and “B” terminals should be connected
through one twisted pair in the cable to the corresponding terminals in the devices being connected to.
The RS-485 interface module is provided with line bias and termination resistors which will be fitted.
A further cable core should be used to connect the “C” terminal to the common terminal in the devices, un-
less the grounding arrangements at each device on the RS-485 network ensures that the local RS-485 reference
voltage (the “C” line) is always near earth potential. A maximum difference of 7 volts is permitted between the
reference voltages of RS-485 devices.
Depending upon local / national electrical regulations, the cable screen should be connected to the earth termi-
nal at one or both ends of the cable. The “SCN” terminal on the RS-485 interface module is connected internally
to the earthing terminal within the unit which the module is fitted and should be used for connection of the
cable screen if it is required to be earthed at the end of the cable where the RS-485 module is.
The comms parameters are fixed:

Baud: 9600.
Data: 8 bits:
Parity: None.
Stop: 1 Stop bit.

All links are factory set and are NOT required to be changed. See drawing below for terminal wiring.
Figure 2.4: RS-485 module
! In normal operation the red LED will remain off and the green LED will remain on.
! The receive yellow LED will flash when it receives modbus data and the yellow transmit LED will flash
when the Gauge Emulator is transmitting Modbus data.

2.5 BPM module
The BPM Communication module should be connected to the Enraf BPM terminals through a twisted pair
screened and steel wire armoured instrumentation cable which is fitted in an ATEX enclosure and used in a
hazardous area. The terminal block on the BPM interface module will accept wires up to 2.5 mm2 and may be
unplugged from the board to assist wiring.
The BPM terminals and associated interface circuit are intended to operate at voltages not exceeding 6 V peak
relative to ‘earth’ ground potential at the signalling frequencies associated with 1,200 / 2,400 Baud BPM trans-
mission.
The interface includes galvanic isolation of 1,500 V between the internal and external circuits.
The centre two “FB” terminals should be connected through the twisted pair cable to the Enraf Gauge or to the
BPM Fieldbus.
nal at one or both ends of the cable. Both of the “SCN” terminals on the BPM interface module are connected
internally to the earthing terminal within the unit which the module is fitted and should be used for connection
of the cable screen if it is required to be earthed at the end of the cable where the BPM module is.
In most cases the receive sensitivity can be left at default, but if receiving BPM data is poor these links can be
adjusted.
The BPM baud rate can be adjusted between 1200 or 2400 baud. At 1200 baud the link should be open, for
2400 baud the link should be closed. After any changes to the jumper links and the Gauge Emulator must be
power cycled.

See drawing below for terminal wiring.
Figure 2.5: BPM Module
! The receive yellow LED will flash when it receives any data and the yellow transmit LED will flash
when the Gauge Emulator is transmitting GPU data.

2.6 TRL/2 module
The TRL/2 Communication module should be connected to the Emerson TRL/2 terminals through a twisted pair
screened and steel wire armoured instrumentation cable which is fitted in an ATEX enclosure and used in a haz-
ardous area. The terminal block on the TRL/2 interface module will accept wires up to 2.5 mm2 and may be
unplugged from the board to assist wiring.
The TRL/2 terminals and associated interface circuit are intended to operate at a fixed baud rate of 4800.
The interface includes galvanic isolation between the internal and external circuits.
The centre two “FB” terminals should be connected through the twisted pair cable to the Emerson Gauge or to
the TRL/2 Fieldbus.
nal at one or both ends of the cable. Both of the “SCN” terminals on the TRL/2 interface module are connected
internally to the earthing terminal within the unit which the module is fitted and should be used for connection
of the cable screen if it is required to be earthed at the end of the cable where the TRL/2 module is.
See drawing below for terminal wiring.
Figure 2.6: TRL/2 Module
when the Gauge Emulator is transmitting TRL/2 data.

2.7 Current Loop module
The Current Loop Communication module should be connected to the terminals through a twisted pair screened
and steel wire armoured instrumentation cable which is fitted in an ATEX enclosure and used in a hazardous area.
The terminal block on the Current Loop interface module will accept wires up to 2.5 mm2 and may be unplugged
from the board to assist wiring.
The Current Loop terminals and associated interface circuit are intended to operate at various baud rates in the
range of 150 - 4800 baud.
The interface includes galvanic isolation between the internal and external circuits.
The centre two “FB” terminals should be connected through the twisted pair cable to the Current Loop gauge
or host.
Depending upon local / national electrical regulations, the cable screen should be connected to the earth ter-
minal at one or both ends of the cable. Both of the “SCN” terminals on the Current Loop interface module are
connected internally to the earthing terminal within the unit which the module is fitted and should be used for
connection of the cable screen if it is required to be earthed at the end of the cable where the Current Loop
module is.
See drawing below for terminal wiring. There is no configuration jumpers required on the board.
Figure 2.7: Current Loop Module
when the Gauge Emulator is transmitting data.

CHAPTER 3
Configuration
3.1 Configuration
The Gauge Emulator has been designed so that configuration is kept to a minimum.
The communication modules will be set up per order requirements.
On power up the Gauge Emulator will auto-configure, this is done by searching for gauges and setting itself up
to suit the gauge type it finds. Auto-configuration may take few minutes depending on the address of the gauge.
The address of the gauge the Gauge Emulator connects to will be the address the host system will need to poll.
If any changes are made to the gauge Emulator configuration using either the SD Card port or the Ethernet port
then it is recommended that the Gauge Emulator is power cycled. Also if any changes are made to the gauge
itself, then it is recommended that the Gauge Emulator is power cycled to pick up the changes from the gauge.
Extra configuration is achieved through the Ethernet or SD card ports.

3.1.1 Web browser configuration using the Ethernet port
Connect the Gauge Emulator to a PC/Laptop or to a network using a standard Ethernet cable. If you are con-
necting direct to a PC/Laptop ensure the IP address of the PC/Laptop is set up accordingly.
Default settings of the Ethernet port and credentials detailed below:
IP address: Fixed: 192.168.1.220
Host name: gaugeemulator
User Name: admin
Password: MHT
All the above settings can be changed once you have logged in, any changes to these parameters will be saved
in the Gauge Emulator flash memory. If the above details are forgotten, they can be recovered using the serial
port which will be described later.
Use a web browser to connect to the Gauge Emulator. The Gauge Emulator has been tested on recent versions
of Chrome, IE, Firefox, Edge, Safari(ipad) and samsung mobile web browser. Once you are logged in you will
enter a home page, where you have a choice of screens you can enter.
There is no logout option, ensure the browser is closed after configuration is complete and this acts as a logout.
Even thou there is a login with password, the Gauge Emulator does not offer integrity relating to the security of
the Gauge Emulator.
If both the SD card and Ethernet ports are used for configuration, for both to have the same configuration, when
any changes are made through the Ethernet port in the parameter mapping screen this will also write the con-
figuration to the SD card, so ensure the SD card is fitted to synchronise configuration, otherwise to synchronise
set the parameters the same using the SD Card configuration tool.
For a success configuration using the web browser ideally configuration needs to be achieved going through
each link from left to right, starting with the network link.

Network
In this screen is where you change the IP address to fixed or to DCHP. When the DHCP checkbox is ticked the
IP address is automatically assigned by the network server. When the DHCP checkbox is unchecked then the IP
address is fixed and a valid IP address must be entered in the IP address text box.
The host name can be changed, this allows a search for host name rather than IP address in the browser.
The Network Mask, Default Gateway, Primary DNS Server and Secondary DNS Server. In most cases these will
not be used so can be left as default.
If you need to revert back to the previous settings before selecting the change button this can be acheived using
the ’Undo’ button.
Once the Network parameters have been changed, for the changes to be saved in the Gauge Emulator flash
memory the ’changed’ button and then the ’OK’ button must be pressed.
There is a link to network statistics, the information in this page details what IP addresses are connected to the
Gauge Emulator, port number and various other information. This screen has a refresh rate of approx 10 seconds
but it can be also refreshed using the manual button.
Figure 3.1: Network

System
In this screen is where the login password is changed.
Enter the new password in the user ’admin’ text box and re-enter the new password in the second text box.
You can revert back by using the ’Undo’ button.
Select the ’Change’ and then the ’OK’ button to save the new password in flash memory. You will then go back
to the home screen. If you select a new screen you will be asked for the new password.
If the 2 passwords entered are different in the text box, when you enter the home screen you will NOT be asked
for the new password when entering a new screen and the previous password will still be used for logging in.
There is one user name which is fixed as ’admin’.
Figure 3.2: System

Port Settings
In this screen is where the Slave driver is selected and port setting are configured.
The first parameter to configure is the slave driver, ensure the slave driver selected marries up with the slave
port communication modules which has been ordered with the Gauge Emulator.
Ensure the correct ports are configured as some slave drivers will support two slave ports and other slave drivers
support one slave port.
Slave port: GPU:- Port 2.

Slave port: TRL2:- Port 2.
Slave port: WM550:- Port 2 and Port 3.
Select the baud rate, parity and the number of data bits for each port which the slave driver supports. En-
sure that the baud rate, parity and the number of data bits marries up with the protocol.
GPU:- Baud rates: 1200/2400. Parity: Odd. Data bits: 7.

TRL2:- Baud rate: 4800. Parity: None. Data bits: 8.
WM550:- Baud rates: 150/300/600/1200/1800/2400/4800/ Parity: Even. Data bits: 8.
The text box to the left displays the current configuration of the port settings and the slave driver. The drop
down list to the right displays the new settings before the ’Update’ button is pressed.
Use the ’Undo’ button to revert back to the original settings.
use the ’Update’ button to apply the new port settings.
Once the port configuration has been updated the configuration will be automatically saved in the Gauge Emu-
lator flash memory and the drop down list will all show ’please select’.
There is no refresh rate on this screen, the screen gets refreshed when the ’update’ or ’Undo’ button is pressed.
Figure 3.3: Port Settings

Configuration
In this screen is where the configuration of the slave driver specific configuration is required. On first selecting
the Configuration link a small screen is entered where you are simply asked to continue, click the button will take
you automatically to the configuration screen associated with the slave driver selected in the port setting screen.
Figure 3.4: Configuration
GPU
There is NO configuration required for the GPU slave driver. In the configuration screen the gauge address is
displayed, this cannot be changed through the web browser, the address of the gauge is achieved automatically.
Figure 3.5: GPU Configuration

TRL/2 Parameter Mapping
The configuration at default is set to the below settings:-
Free Water:
Analog input 1 (0x06, and 0x1E – 0x1F). Units will be as per level units.
Observed Density:
Analog input 2 (0x07, and 0x20 – 0x21) and HART input 3 (0x24 – 0x25), and input register 4656. Units kg/m3.
P1 pressure:
HART input 1 (0x28 – 0x29). Units will be derived from gauge.
P2 Pressure:
Analog input 3 (0x08). Units millibar.
P3 Pressure:
HART input 2 (0x26 – 0x27). Units will be derived from gauge.
In this screen is where the configuration of the TRL/2 registers are achieved.
Although there is some guidance given on the TRL/2 protocol and registers, it is important that the user has
further knowledge and competence when mapping of the registers.
On power up of the Gauge Emulator it will do a search for devices and will do some auto-configuration.
The Gauge address will be automatically configured in the Gauge address box in the Parameter Mapping screen.
This address will be the address the Emerson host will poll for. The DAU address will be exact 100 above the
gauge address which the Gauge Emulator will also emulate.
Level, Temperature, Temperature elements and status have fixed registers and do not need mapping.
The units, such as metric or imperial will be automatic and will be read from the connected gauge.
Analog 1, Analog 2, HART 1, HART 2, HART 3, Analog current 1, Analog current 2 and Analog current 3 are all reg-
isters in the Gauge which can have parameters mapped to them if the host requires parameter from that register.
DAU Current 1, DAU Current 2, DAU Current 3 and DAU Current 4 are registers within a Slave or Independent
DAU which can have parameters mapped to them. The Gauge Emulator will emulate either a slave or indepen-
dent DAU with no extra configuration.
It is required that the user knows from the host system what parameters are required from what registers before
configuration.
If an FCU2160 is polling the Gauge Emulator the FCU2160 version is required if the level units are imperial. If
you do not know the FCU2160 version then select unknown and this will default to a new version.
Pressure scaling applies a multiplication factor to the pressure value read in from the gauge. The value en-
tered in this register simply multiplies the value read from the gauge. For example, if the pressure read from
the gauge is Bar and this needs to be milliBars in TRL/2 register then enter 1000 in the scaling text box. This
scaling is only for integer registers (DAU C1, DAU C2, DAU C3, DAU C4, Analog C1, Analog C2 and Analog C3) for
both metric and imperial units. For all other registers there will be no scaling as these registers are floating point.
The text box to the left displays the current configuration which will place the parameter from the gauge into
the TRL/2 register. The drop down list to the right displays the new settings before the ’Update’ button is pressed.

use the ’Update’ button to apply the new mapping.
Once the parameters have been mapped these will be saved in the Gauge Emulator flash memory and the drop
down list will all show ’please select’.
there is no refresh rate on this screen, the screen gets refreshed when the ’update’ or ’Undo’ button is pressed.
Figure 3.6: Parameter Mapping

WM550 Configuration
In this screen is where some of the WM550 tasks are configured.
Although there is some guidance given on the WM550 tasks, it is important that the user has further knowledge
and competence of the WM550 protocol.
On power up of the Gauge Emulator it will do a search for devices and will do some auto-configuration.
The Gauge address will be automatically configured in the Gauge address box in the configuration screen. This
address will be the address the Whessoe WM550 host will poll for. It is important that the address of the gauge
is between 1 - 63 to marry up with the WM550 protocol.
WM550 task 32 holds an ID code which is used by some Whessoe host systems to determine the gauge type
and what base tasks to poll for.
ID code 2000:- Base task 27/28.
Select the appropriate ID code from the drop down list, if the host does not use an ID code then this parameter
can be left to ’any’ value.
Most parameters are fixed to Whessoe tasks. Whessoe task for pressure only supports one pressure, in the
configuration screen, base pressure (P1), Product pressure (P2) or Vapour pressure (P3) can be mapped to the
WM550 pressure tasks.Use the drop down list to choose the appropriate pressure.
All parameters units are fixed at metric, level:-mm, Temperature:- Degree C. Pressure:- Bar. Density:- KG/M3.
Pressure scaling applies a multiplication factor to the pressure value read in from the gauge. The value entered
in this register simply multiplies the value read from the gauge. For example if the pressure read from the gauge
is Bar and 10 is entered then the value in the pressure task will be multiplied by 10. In most cases this parameters
needs to be left at 10.
The text box to the left displays the current configuration which will place the parameter from the gauge into
the WM500 task. The drop down list to the right displays the new settings before the ’Update’ button is pressed.
use the ’Update’ button to apply the new mapping.
Once the parameters have been configured these will be saved in the Gauge Emulator flash memory and the
drop down list will all show ’please select’.
there is no refresh rate on this screen, the screen gets refreshed when the ’update’ or ’Undo’ button is pressed.
Vapour Temperature note:- Some host systems may automatically pick up the Vapour temperature from the
16th element. Please be aware of this especially when using task 51.

Figure 3.7: WM550 Configuration

Engineers Screen
This screen has no configuration and is used for displaying engineering data.
The master port is the port which the gauge connects to and the gauge type.
There are two slave ports listed, the information here shows which port will be used and what driver it is, the
slave ports are determined by what driver is selected in the port settings.
Operation type ’One to one’ means only one gauge is polled for by the Gauge Emulator.
Operation type ’One to Many’ means the Gauge Emulator will poll and emulate up to 32 gauges depending on
the gauge type connected.
Firmware version, Firmware CRC and Firmware timestamp is information needed for support.
Modbus messages sent displays the number of polls the Gauge Emulator has made, this value is reset on a power
cycle.
Modbus timeouts displays the number of ’no replies’ the Gauge Emulator has received from a gauge, this value
is reset on a power cycle.
For diagnostics and debugging, the Gauge Emulator has four buttons, these buttons allow the RAW comms data
to be printed to the Gauge Emulator RS232 port. So by connecting a PC/Laptop with a serial port (and comms
logging software’) to the Gauge Emulator, the comms RAW data can be captured and emailed to our office for
diagnostics.
Details on the RS232 serial will be described later.
This screen has a refresh rate of 10 seconds, if you require data immediately use the ’refresh screen’ button.
Figure 3.8: Engineers Screen

Live Data
This screen displays the live data from the gauge.
The data displayed shows the parameter value, units, status and status code.
The status code is the raw status value from the gauge.
The status (PASS or FAIL) is how the Gauge Emulator interprets the status code and value. This status will be
passed onto the slave comms. This status will give an indication when troubleshooting.
The gauge type is determined from the gauge modbus register values.
The refresh rate is 10 seconds, if data is required immediately then the refresh button can be used.
Figure 3.9: Live Data

Gauge Commands
This screen allows gauge commands to be sent direct to the gauge.
It is important the the gauge type is a ’servo’ gauge. The gauge type is determined in the live data screen.
When a gauge command is issued the displacer position and gauge status is shown to indicate the action has
been successful.
Press one of the buttons to issue the appropriate command.
If a gauge command sent is the same as the previous command then the command may not action, this will be
seen mainly with water and density, this is due to the nature of the gauge unable to accept two commands the
same, to overcome this problem, issue a freeze or unstow between two commands of the same.
The refresh rate is 6 seconds, if data is required immediately then the refresh button can be used.
Figure 3.10: Gauge Commands

3.1.2 SD card configuration
Configuration can be achieved through the SD card port, as a minimum requirement, the PC / Laptop using this
tool must have a .NET framework 4.6.1 or newer, Windows OS and an SD card reader.
Firstly ensure the micro SD card has a text file on it with the name ’Config.txt’. The name of the SD card is not
limited and can have any name.
Launch the SD card configuration tool program and configure the Gauge Emulator to the desired settings.
The first page entered is the general setting page, in this page is where the baud rate, parity and data bits are
set. Ensure the correct parameters are set which is associated with the slave port driver protocol. Also ensure
that the correct port is configured. See web browser configuration page in this manual for further information
on settings.
Select the driver from the drop down list, when the next button is pressed the configuration page entered will
be determined by the driver selected.
Figure 3.11: SD Card Configuration Tool General Settings

GPU Driver
All configuration is automatic for the GPU driver so no configuration is required.
Figure 3.12: GPU Driver

TRL/2 Driver
Parameter mapping is the same method as configuration through the Ethernet port, choose the parameter for
the appropriate TRL/2 registers.
Figure 3.13: TRL2 Driver

WM550 Driver
WM550 configuration is the same method as configuration through the Ethernet port, choose the appropriate
settings.
Figure 3.14: WM550 Driver

Selecting apply or ’save to SD Card’ icon will save the configuration direct to the ’Config.txt’ file on the SD Card.
If no SD card is available at the time of configuration then the Config,txt file can be saved to the PC and copied
later to the SD Card using the ’save as’ icon
If you require to see the configuration on the SD card, this can be achieved by opening ’Config.txt’ file on the SD
card using the open icon from the general setting page, the parameters will then be displayed.
Once configuration is complete the SD card can now be removed from the PC / Laptop.
The SD card can be plugged into the Gauge Emulator when the Gauge Emulator is powered off.
When the Gauge Emulator is powered up, wait for all 4 LED’s to turn on to confirm the configuration has been
successful, once all the LED’s have turned off the SD card can be removed. This process will take approx 10
seconds.
When the Gauge Emulator is powered off, plug the SD card into the SD card port, (the lid of the Gauge Emulator
can be put back on), Power the Gauge Emulator up, await approx 10 seconds then the Gauge Emulator can now
be turned back off, lid removed and SD card removed.
Once SD card configuration is successful, the configuration is saved in the flash memory of the Gauge Emulator
so the SD card is no longer required for normal operation.
All the LEDs must turn on for the configuration to be successful, if one or more of the LED’s do not turn on, then
there has been a problem, see the drawing below to indicate where the problem may lie.
Figure 3.15: SD Card LED Status

3.2 Alarms
The Gauge Emulator will read the alarms status in Modbus register 5164 (alarm 1). The four alarms HH, H, L, LL
will be passed to the slave comms.
In the GPU and WM550 protocol this will be the appropriate designated register and bits. In the TRL/2 protocol
this will be relay status register (0x2B).
Low and low low will turn relay 1 ON.
High and High high will turn relay 2 ON.
The alarms follow the below configuration in the E+H gauge.
Figure 3.16: Alarms

CHAPTER 4
RS232 port
4.1 RS232 port

There is a RS232 port on the Gauge Emulator, see drawing, this port is used for basic user data, Firmware up-
grades and RAW data diagnostics.
The parameters are fixed:-

Baud rate: 38400.
Data bits: 8.
Parity:
None.
Stop bits: 1.
On power up or typing the command ’info’ (lower case), data will be printed to the serial port.
DHCP status, IP address and network mask will be printed.
Login password and host name will also be printed. This allows you to login if you have forgotten the login pass-
word when using the Ethernet port.
The firmware CRC is also printed.
When using the RAW data print function in the Engineers screen of the web browser, the RAW data will be
printed to this port. This data can be captured, saved and email for further diagnostics.
Firmware upgrades can be achieved through this port and are detailed in another document.

CHAPTER 5
Operation
5.1 Power up
Once the appropriate jumper links have been set on the comms modules and everything has been wired up the
the Gauge Emulator can be powered up.
On power up the Gauge Emulator will do nothing and wait for between 45 to 60 seconds, this is to allow time
for the Gauge(s) to also power up if they are on the same main supply as the Gauge Emulator. During this period
the Status Indicators 2 red LED will be lit to indicate the Gauge Emulator is waiting. The Status Indicators 2 green
LED will flash and will continue to flash all the time the Gauge Emulator is powered up.
5.2 Searching for gauges

Once the power up is complete the Gauge Emulator will start a search which is part of the auto-configuration
sequence. The Gauge Emulator searches the gauges by polling for an address starting at 1 or 0 depending on
the gauge type connected, it will then increment the gauge address until the Gauge Emulator sees a response, if
the Gauge Emulator is a 1 - 1 it will then start polling for data. If the Gauge Emulator is a 1 - many it will continue
to increment the gauge address and search for more gauges until a predetermined number of gauges have been
found or the maximum gauge address is reached, then the Gauge Emulator will start polling for data.
5.3 Polling for data

Once the searching sequence is complete the Gauge Emulator will go into normal operation and poll for gauging
data, this data will then be available on the slave port for the host to read.

CHAPTER 6
Troubleshooting
6.1 Troubleshooting
Symptom: No red LED and no flashing green LED.
Possible cause: No mains power or fuse has blown.
Remedial Action: Check power supply or check the mains input fuse.
Symptom: Mains input fuse blows repeatedly.

Possible cause: Equipment fault.
Remedial Action: Replace complete Gauge Emulator electronics.
Symptom: Red LED never goes out.

Possible cause: Mains supply fluctuation or microcontroller fault.
Remedial Action: Check mains supply or replace complete Gauge Emulator electronics.
Symptom: Master port transmit LED always flashes but receive LED never flashes.
Possible cause: No communication with gauge.
Remedial Action: Check cabling and configuration of gauge such as baud rate.
Symptom: Slave receive LED always flashes but master LED never flashes.
Possible cause: No communication with the host.
Remedial Action: Check cabling, configuration and baud rates etc in the host.

CHAPTER 7
Maintenance
7.1 Maintenance
The thread of the lid of the Gauge Emulator should be periodically regreased with silicone grease.
The Gauge Emulator contains no user serviceable parts. In the event of failure or damage the following parts
may be replaced by suitable trained and competent service personnel :
Mains Input Fuse: 20 x 5 mm cartridge, time-lag / slow-blow / anti-surge, 1.6 A, HBC type.
Master Interface Module.
Slave Interface Module.
Power Supply Unit.
In the case of failure of any other part of the Gauge Emulator, it is recommended that the unit be replaced as a
whole.
Technical assistance
Technical assistance may be obtained from the Manufacturer:
MHT Technology Ltd

Harelands Courtyard offices
Moor Road, Melsonby
Richmond, North Yorkshire
DL10 5NY, England
Tel: +44 (0) 1748 828 820

email: support@mht-technology.co.uk

CHAPTER 8
Appendix
8.1 GPU Description

This Gauge Emulator will poll only one E+H NMS8x / NMR8x / NRF8x gauge using the Modbus protocol. The
slave port is a Honeywell Enraf GPU over BPM port. The configuration of the Gauge Emulator connected to the
E+H gauge appears to a Honeywell Enraf host system as a 811/873/854 or 990 gauge.
The parameters which this version of Gauge Emulator supports are:-
Figure 8.1: GPU Items

Figure 8.2: GPU Items

8.2 TRL/2 Description
This Gauge Emulator will poll only one E+H NMS8x / NMR8x / NRF8x gauge using the Modbus protocol. The
slave port is a Emerson TRL/2. The configuration of the Gauge Emulator connected to the E+H gauge appears to
a Emerson host system as a REX or Raptor gauge.
Figure 8.3: TRL/2 Registers

Figure 8.4: TRL/2 Registers
Figure 8.5: Raptor (Tankhub) Registers

8.3 WM550 Description
This Gauge Emulator will poll only one E+H NMS8x / NMR8x / NRF8x gauge using the Modbus protocol. There
are two slave ports which are the Whessoe WM550 protocol over current loop. The configuration of the Gauge
Emulator connected to the E+H gauge appears to a Whessoe host system as a Whessoe WM550 gauge.
Figure 8.6: WM550 Tasks

Figure 8.7: WM550 Tasks

8.4 Declaration of Conformity
Figure 8.8: Declaration of Conformity

GaugeEmulator WM550 TRL2 BPM I and C Manual

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Gauge Emulator

Installation and Commissioning

Product Version : 1.0.0

Master Port : Modbus E+H 8x gauge

Slave port : Honeywell Enraf GPU over BPM

Operation : One to one

Document produced : October 31, 2018

1.1 Introduction to the Gauge Emulator

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2.1 Mechanical Installation

Fixing holes are suitable for M10 or M12 bolts.

Figure 2.1: Enclosure

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! Any unused holes should be blanked oﬀ accordingly.

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Figure 2.2: Mechanical layout

Port 1:- Master port, Nxx8x Modbus RS485 gauge.

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Figure 2.3: Mains input terminals

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The comms parameters are ﬁxed:

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Figure 2.4: RS-485 module

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Figure 2.5: BPM Module

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See drawing below for terminal wiring.

Figure 2.6: TRL/2 Module

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Figure 2.7: Current Loop Module

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The communication modules will be set up per order requirements.

Extra conﬁguration is achieved through the Ethernet or SD card ports.

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Default settings of the Ethernet port and credentials detailed below:

IP address: Fixed: 192.168.1.220

Host name: gaugeemulator

User Name: admin

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Figure 3.1: Network

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There is one user name which is ﬁxed as ’admin’.

Figure 3.2: System

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Slave port: GPU:- Port 2.

GPU:- Baud rates: 1200/2400. Parity: Odd. Data bits: 7.

Use the ’Undo’ button to revert back to the original settings.

use the ’Update’ button to apply the new port settings.

Figure 3.3: Port Settings

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Figure 3.4: Conﬁguration

Figure 3.5: GPU Conﬁguration

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use the ’Update’ button to apply the new mapping.

Figure 3.6: Parameter Mapping

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Use the ’Undo’ button to revert back to the original settings.

use the ’Update’ button to apply the new mapping.

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Figure 3.8: Engineers Screen