Exertherm Manual MA-141-1-EN (UCP)

820008
Exertherm® Design, Installation

& Operation Manual
MA-141-1-EN
Exertherm® Design, Installation & Operation Manual
1. VERSION CHANGE CONTROL RECORD

Version No Reason for Change Created by Approved by Date of Release
MA-141-1-EN New product: John Hope John Hope 1st August 2022
Exertherm Datacard
Lisa John-
800208
Kennedy
EM Cable Sensor
800115
Contact Sensor
800116
THIS IS A CONTROLLED DOCUMENT:

UPON RECIEPT OF A NEW VERSION, PLEASE DESTROY ALL PREVIOUS VERSIONS HELD AND UPDATE
ANY RECORDS / PROCEDURES WITH THE CURRENT VERSION
Page 2 of 89 ©Exertherm 2022 MA-141-1-EN

Global: +44 (0)1582 461123 USA: +1 646 512 5727 E: Sales@Exertherm.com
2. USING THIS MANUAL
This manual contains information that is fundamental both to the operation of the Exertherm
system and to operator safety. Please read the manual thoroughly prior to commencing any
work.
The general hazard (ISO7000-0434) symbol is used where non-observance of the
information/instruction might cause hazards to person(s) or the equipment.

Contents
1. Version Change Control Record ................................................................................................................ 2
2. Using this Manual .................................................................................................................................... 3
3. Ownership, Notes and Critical Disclaimers ............................................................................................... 8
Notices: ................................................................................................................................................................................. 8
Intellectual Property, Patents, Trade Marks and Registered Designs ................................................................................... 8
Standards and approvals ...................................................................................................................................................... 9
Personnel Qualification and Training.................................................................................................................................... 9
Warranty............................................................................................................................................................................... 9
Live Working ....................................................................................................................................................................... 10
4. Exertherm® System ................................................................................................................................11
Exertherm Integration Options ........................................................................................................................................... 12
Core Components ............................................................................................................................................................... 13
Exertherm Non-Contact Infrared (IR) Sensor...................................................................................................................... 13
Exertherm EM Cable Sensor ............................................................................................................................................... 13
Exertherm Contact / Ambient Sensor ................................................................................................................................. 13
Exertherm Modbus Datacard ............................................................................................................................................. 14
ARM XL & loadmap ............................................................................................................................................................. 14
5. Definitions ..............................................................................................................................................15
6. Where to Monitor ..................................................................................................................................16
Switchgear / Switchboards ................................................................................................................................................. 16
MCC .................................................................................................................................................................................... 17
Transformers ...................................................................................................................................................................... 17
7. Install Guide – Infrared Sensors ..............................................................................................................18
General Advice.................................................................................................................................................................... 18
Mounting Distances ............................................................................................................................................................ 19
Target Zone – Sensor Orientation....................................................................................................................................... 20
Optimum Viewing Angle ..................................................................................................................................................... 21
Target Zone – Surface Finishes ........................................................................................................................................... 22
Acceptable Surfaces… ......................................................................................................................................................... 22
Unacceptable Surfaces…..................................................................................................................................................... 23
Target Zone - Dimensions ................................................................................................................................................... 24
IR Sensor Mounting options ............................................................................................................................................... 25
IR Sensor - Cable Length ..................................................................................................................................................... 28
8. Brackets .................................................................................................................................................29
Exertherm IR Sensor Support Brackets ............................................................................................................................... 29
9. Install Guide - EM Cable Sensors .............................................................................................................30
EM Cable Sensor Placement ............................................................................................................................................... 31
EM Cable Sensor Temperature Drop .................................................................................................................................. 32
EM cable sensor placement – multiple cables .................................................................................................................... 33
6 cables per phase - use 2 EM Cable Sensors ..................................................................................................................... 33
7 cables per phase – use 3 EM cable sensors ..................................................................................................................... 33
9 cables per phase – use 3 EM cables sensors .................................................................................................................... 34
12 cables per phase – use 4 EM cable sensors ................................................................................................................... 34
14 cables per phase – use 6 EM cable sensors ................................................................................................................... 35
EM Cable Sensor - Cable Length ......................................................................................................................................... 36
EM Cable Insulation Rating ................................................................................................................................................. 36
10. Install Guide – Contact/Ambient Sensors ................................................................................................37
Contact/Ambient Sensor Placement .................................................................................................................................. 37
Contact/Ambient Sensor – Cable Length ............................................................................................................................ 38
11. Cable Routing .........................................................................................................................................39
12. Exertherm Modbus Datacard ..................................................................................................................40
Safety and Use of Equipment – Exertherm Modbus Datacard ........................................................................................... 40

Modbus Datacard ............................................................................................................................................................... 41

Installation .......................................................................................................................................................................... 41
To Mount ............................................................................................................................................................................ 41
To Remove .......................................................................................................................................................................... 42
Reset Switch ....................................................................................................................................................................... 42
Factory Reset ...................................................................................................................................................................... 42
Diagnosis LEDs .................................................................................................................................................................... 43
Internal Temperature Sensor ............................................................................................................................................. 43
Connections, Sensors and Power Supply ............................................................................................................................ 44
IR Sensor Connection to Datacard ...................................................................................................................................... 45
EM Cable Sensor Connection to Datacard .......................................................................................................................... 46
Contact/Ambient Sensor Connection to Datacard ............................................................................................................. 47
Power connection to Datacard ........................................................................................................................................... 48
Linking Datacards ............................................................................................................................................................... 49
Within a Single Item of Equipment ..................................................................................................................................... 50
Between Items of Equipment ............................................................................................................................................. 50
13. Pre-Commissioning Preparation ..............................................................................................................51
Exertherm Datacard Configuration Tool Installation .......................................................................................................... 51
14. Exertherm Datacard Configuration Tool ..................................................................................................54
Main Screen ........................................................................................................................................................................ 54
Menu Item Settings: ........................................................................................................................................................... 54
Comms Settings Menu ........................................................................................................................................................ 55
Comms Error message ........................................................................................................................................................ 56
Commissioning the Datacard .............................................................................................................................................. 57
Search Node: ...................................................................................................................................................................... 57
System Parameters: ............................................................................................................................................................ 59
Channel Configuration ........................................................................................................................................................ 60
Gain Factor Adjustment ...................................................................................................................................................... 61
Program Datacard............................................................................................................................................................... 62
Monitor Mode .................................................................................................................................................................... 64
Datacard Configuration Tool Support ................................................................................................................................. 66
15. Alarms: ...................................................................................................................................................67
Suggested Alarm Levels: ..................................................................................................................................................... 67
16. Modbus Functions & Registers: ...............................................................................................................68
Node range ......................................................................................................................................................................... 68
Details of Modbus Registers 001…008 ............................................................................................................................... 68
Signed Integer..................................................................................................................................................................... 68
17. Acceptance Testing Procedure ................................................................................................................69
IR Sensor Test Procedure .................................................................................................................................................... 69
Exertherm Verification Device (EVD) Instructions .............................................................................................................. 70
IR Sensor Pass/Fail Criteria ................................................................................................................................................. 72
EM Cable Sensor Test Procedure ........................................................................................................................................ 72
EM Cable Sensor Testing Instructions................................................................................................................................. 73
18. HiPot Testing ..........................................................................................................................................75
Outline ................................................................................................................................................................................ 75
Design Checklist .................................................................................................................................................................. 75
Datacard Connections ........................................................................................................................................................ 76
Sensor Connection to Datacard .......................................................................................................................................... 76
Power Connection to Datacard .......................................................................................................................................... 76
Testing Procedure ............................................................................................................................................................... 76
19. Type Testing / Design Verification ...........................................................................................................79
Purpose............................................................................................................................................................................... 79
Procedure: Initially electrical circuits under test not energised ......................................................................................... 80
Procedure: with electrical circuits under test energised. ................................................................................................... 80
20. Routine Maintenance .............................................................................................................................82

General ............................................................................................................................................................................... 82
21. Troubleshooting .....................................................................................................................................83
Datacard Troubleshooting Guide........................................................................................................................................ 83
22. Technical Datasheets ..............................................................................................................................88
Data Sheet – IR Sensor Gain Matrix .................................................................................................................................... 88
Exertherm Install & Configuration Record .......................................................................................................................... 89
TABLE OF FIGURES
FIGURE 1 EXERTHERM SYSTEM OVERVIEW ...................................................................................................................................................... 11
FIGURE 2 EXERTHERM INTEGRATION OPTIONS ................................................................................................................................................. 12
FIGURE 3 EXERTHERM IR SENSOR.................................................................................................................................................................. 13
FIGURE 4 EXERTHERM EM CABLE SENSOR ...................................................................................................................................................... 13
FIGURE 5 EXERTHERM CONTACT/AMBIENT SENSOR .......................................................................................................................................... 13
FIGURE 6 EXERTHERM MODBUS DATACARD .................................................................................................................................................... 14
FIGURE 7 EXERTHERM ARM XL .................................................................................................................................................................... 14
FIGURE 8 WHERE TO MONITOR .................................................................................................................................................................... 16
FIGURE 9 IR SENSOR - DESIGN ADVICE (SIDE VIEW).......................................................................................................................................... 18
FIGURE 10 BUSBAR / CABLE CONNECTION ...................................................................................................................................................... 19
FIGURE 11 POSSIBLE SENSOR LOCATIONS ....................................................................................................................................................... 20
FIGURE 12 VIEWING ANGLE – ELEVATION (SIDE VIEW) ...................................................................................................................................... 21
FIGURE 13 VIEWING ANGLE –PLAN (BIRDS EYE VIEW) ....................................................................................................................................... 21
FIGURE 14 ACCEPTABLE SURFACES ................................................................................................................................................................ 22
FIGURE 15 UNACCEPTABLE SURFACES ............................................................................................................................................................ 23
FIGURE 16 PAINTED TARGET ZONE ................................................................................................................................................................ 24
FIGURE 17 SENSORS MOUNTED OUTSIDE BARS VIEWING INWARD ........................................................................................................................ 25
FIGURE 18 SENSORS MOUNTED IN-BETWEEN BARS ........................................................................................................................................... 25
FIGURE 19 SENSORS MOUNTED AT AN ANGLE (UP TO 45°) ................................................................................................................................. 26
FIGURE 20 SENSORS MOUNTED ABOVE, POINTING DOWN ONTO THE TOP OF BARS .................................................................................................. 26
FIGURE 21 SENSORS MOUNTED VIEWING THE VERTICAL DROPS ........................................................................................................................... 27
FIGURE 22 SENSORS MOUNTED OUTSIDE TWIN BARS VIEWING INWARD ................................................................................................................ 27
FIGURE 23 SENSORS MOUNTED IN-BETWEEN TRIPLE BARS .................................................................................................................................. 27
FIGURE 24 IR SENSOR CABLE EXTENSION........................................................................................................................................................ 28
FIGURE 25 EM CABLE SENSOR INSTALLATION.................................................................................................................................................. 31
FIGURE 26 CABLE SENSOR TEMPERATURE DROP ............................................................................................................................................... 32
FIGURE 27 6 CABLES PER PHASE - USE 2 EM CABLE SENSORS .............................................................................................................................. 33
FIGURE 28 7 CABLES PER PHASE – USE 3 EM CABLE SENSORS ............................................................................................................................. 33
FIGURE 29 9 CABLES PER PHASE - USE 3 EM CABLE SENSORS ............................................................................................................................. 34
FIGURE 30 12 CABLES PER PHASE - USE 4 EM CABLE SENSORS ............................................................................................................................ 34
FIGURE 31 14 CABLES PER PHASE - USE 6 EM CABLE SENSORS ............................................................................................................................ 35
FIGURE 32 EM CABLE SENSOR - CABLE EXTENSION .......................................................................................................................................... 36
FIGURE 33 CONTACT/AMBIENT SENSOR - CABLE EXTENSION .............................................................................................................................. 38
FIGURE 34 EXERTHERM DATACARD OVERVIEW ................................................................................................................................................ 41
FIGURE 35 MOUNTING A DATACARD ............................................................................................................................................................. 41
FIGURE 36 REMOVING A DATACARD .............................................................................................................................................................. 42
FIGURE 37 IR SENSOR TERMINATIONS – CONNECTION TO DATACARD .................................................................................................................. 45
FIGURE 38 EM CABLE SENSOR TERMINATIONS – CONNECTION TO DATACARD....................................................................................................... 46
FIGURE 39 CONTACT/AMBIENT SENSOR TERMINATIONS – CONNECTION TO DATACARD .......................................................................................... 47
FIGURE 40 POWER SUPPLY TERMINATIONS – CONNECTION TO DATACARD............................................................................................................ 48
FIGURE 41 LINKING DATACARDS ................................................................................................................................................................... 49
FIGURE 42 DATACARD PATCH CABLE PIN OUT .................................................................................................................................................. 49
FIGURE 43 CONFIG TOOL - MAIN SCREEN ....................................................................................................................................................... 54

FIGURE 44 CONFIG TOOL - COMMUNICATION SETTINGS .................................................................................................................................... 55

FIGURE 45 COMMS ERROR MESSAGE ............................................................................................................................................................ 56
FIGURE 46 CONFIG TOOL - SEARCH FOR A DATACARD ....................................................................................................................................... 58
FIGURE 47 CONFIG TOOL - SETTING SYSTEM PARAMETERS ................................................................................................................................. 59
FIGURE 48 CONFIG TOOL - SELECTING THE SENSOR TYPE ................................................................................................................................... 60
FIGURE 49 CONFIG TOOL – IR.EM-06.SC-DELTA T GAIN FACTOR ADJUSTMENT ................................................................................................... 61
FIGURE 50 CONFIG TOOL - PROGRAMMING THE DATACARD ............................................................................................................................... 62
FIGURE 51 CONFIG TOOL - MONITOR MODE .................................................................................................................................................. 64
FIGURE 52 DATACARD CONFIG TOOL SUPPORT ................................................................................................................................................ 66
FIGURE 53 POWER SOCKET .......................................................................................................................................................................... 71
FIGURE 54 EVD LEDS ................................................................................................................................................................................ 71
FIGURE 55 AMBIENT READING ..................................................................................................................................................................... 71
FIGURE 56 HEATED READING ....................................................................................................................................................................... 71
FIGURE 57 HIPOT TESTING – POWER SUPPLY ISOLATION ................................................................................................................................... 77
FIGURE 58 HIPOT TESTING – DISCONNECT GND TERMINALS ............................................................................................................................. 77
FIGURE 59 HIPOT TESTING - EXERTHERM SYSTEM ISOLATION ............................................................................................................................. 78
TABLES
TABLE 1 DEFINITIONS .................................................................................................................................................................................. 15
TABLE 2 PATCH CABLES ............................................................................................................................................................................... 50
TABLE 3 SUGGESTED ALARM LEVELS .............................................................................................................................................................. 67
TABLE 4 IR SENSOR VERIFICATION VALUES ...................................................................................................................................................... 72

3. OWNERSHIP, NOTES AND CRITICAL DISCLAIMERS

NO PART OF THIS MANUAL MAY BE COPIED OR REPRODUCED VIA ANY MEANS WITHOUT THE PRIOR
WRITTEN CONSENT OF EXERTHERM. THIS MANUAL & IT’S CONTENTS ARE SUBJECT TO CHANGE
WITHOUT NOTICE.
This document, including all the descriptions within it, assumes that the user is conversant with the
operation and uses of basic control and monitoring systems.
In addition, this document does not include any specific documentation concerning the systems
with which integration takes place. The user should seek additional information from the supplier’s
documentation for each of the connected systems.
Where devices such as display panels and personal computers are used, we have assumed that the
user will either be familiar with the operation of the devices or will be able to familiarise themselves
with the information supplied with the equipment.
The utility, configuration, terminal or stream modes of the connected systems enable all control
parameters to be changed. Competent persons only should carry this out, and it is strongly
recommended that any changes made be recorded at the time of the changes. Note that if a change
is to be made, a backup of the systems concerned should be made before this where possible.
NOTICES:
The information, products and specifications, configurations, and other technical information
regarding the products and data contained in this document are subject to change without notice.
All the statements, technical information, and recommendations contained in this document are
believed to be accurate and reliable but are presented without warranty of any kind, and users must
take full responsibility for the application of any products or data specified in this document.
IN NO EVENT SHALL EXERTHERM, OR ITS SUPPLIERS BE LIABLE FOR ANY INDIRECT, SPECIAL,
CONSEQUENTIAL, OR INCIDENTAL DAMAGES, INCLUDING, WITHOUT LIMITATION, LOST PROFITS OR
LOSS OR DAMAGE TO EQUIPMENT OR DATA OF ANY KIND WHATSOEVER ARISING OUT OF THE USE
OR INABILITY TO USE THIS DOCUMENT, EVEN IF EXERTHERM HAS BEEN ADVISED OF THE
POSSIBILITY OF SUCH DAMAGES.
THIS LIMITATION OF LIABILITY WILL PREVAIL OVER ANY OTHER TERMS & CONDITIONS RELATING TO
THE SUPPLY OF EXERTHERM PRODUCTS / SERVICES.
INTELLECTUAL PROPERTY, PATENTS, TRADE MARKS AND REGISTERED DESIGNS

Exertherm is a registered trademark. The infrared (IR), EM Cable Sensors and LoadMap software,
are patent protected.
The Exertherm suite of products including but not limited to; Exertherm, Exertherm LoadMap,
IRt/c.EM & EM Cable Sensor contain proprietary information and intellectual property of
Exertherm. Exertherm will vigorously protect itself in the event of any misuse of any or all such
intellectual property.
All other products or services referred to in this document are the trademarks, service marks, or
product names of their respective holders.

STANDARDS AND APPROVALS

Exertherm IR, EM Cable, Contact / Ambient sensors, and the Exertherm Modbus Datacard are all
approved to UL 61010-1 3rd edition and CAN/CSA C22.2 No. 61010-1 3rd edition.
Exertherm IR, EM Cable, Contact / Ambient sensors and the Exertherm Modbus Datacard are all CE
approved.
Exertherm declare that all our components are produced in accordance with EU Directive
2011/65/EU requirement for RoHS Compliance.
PERSONNEL QUALIFICATION AND TRAINING

It is a mandatory requirement that all personnel involved in the installation and commissioning of
Exertherm IR Sensors, EM Cable Sensors and Datacards must have completed & passed all online
training modules before equipment is installed/commissioned.
If Exertherm product is not installed/used following the instructions within the manual/online
training, then this may invalidate warranties.
It is assumed those involved in designing Exertherm into electrical infrastructure have received and
are conversant with the contents of this document.
It is the responsibility of the organisation performing the installation / configuration /
commissioning of the Exertherm products to ensure the competency, and supervision of those
undertaking such tasks, together with all necessary safety procedures in accordance with
international, national, regional, and local regulations and codes. Only persons who have the
requisite level of knowledge, skill and appropriate training should install Exertherm products.
WARRANTY
Exertherm IR Sensor, EM Cable Sensor, Contact / Ambient Sensor, Modbus Datacard & ARM XL
Return/Warranty Policy
Exertherm offers a lifetime warranty on IR Sensors, EM Cable Sensors and Contact / Ambient
Sensors from date of sale. We warrant that these products will be free of defects in material and
workmanship and will repair or replace the returned product at no charge during that period. The
warranties are void if the product is misused, mishandled or installed incorrectly (not in accordance
with the methods and procedures specified in this document); keeping the products within specified
temperatures.
Exertherm offers a 2 year warranty on all other Exertherm product from date of sale. We warrant
that these products will be free of defects in material and workmanship and will repair or replace
the returned product at no charge during that 2 year period. The warranty is void if the product is
misused, mishandled or installed incorrectly.
The warranty is conditional upon the above caveats and strictly limited to the replacement cost of
the Sensors / Datacard / ARM XL. Labour costs associated with removal of Sensors / Datacards /
ARM XL and/or re-installation are excluded, as is any consequential loss resulting from the Sensor /
Datacard / ARM XL failure.
Exertherm reserves the right to examine and test any returned products to determine the cause of
failure. No returned products will be accepted prior to issue of a Return Material Authorization
(RMA) number by Exertherm.
Please contact Exertherm if you have any questions – support@Exertherm.com, current telephone
numbers can be found at www.Exertherm.com .

LIVE WORKING
DO NOT PERFORM ANY ACTIVITY ON A PIECE OF LIVE SWITCHGEAR. FAILURE TO COMPLY WITH
THESE AND OTHER NATIONAL, REGIONAL OR LOCAL HEALTH AND SAFETY
REGULATIONS/GUIDELINES COULD RESULT IN PERMANENT INJURY OR DEATH.
Prior to undertaking any work the operator MUST ensure that all busbars, connections and sources
of energy are totally isolated and checked prior to any works taking place this should be completed
by a competent trained electrical engineer.
All energy sources onto the panel must be isolated, removed and locked out to prevent the panel
being re-energised while any works are taking place. If the panel being tested is part of an existing
installation then all connections should be bonded to earth potential as an extra precaution and
also to stop any possible back feed from other devices.

4. EXERTHERM® SYSTEM
Figure 1 Exertherm System Overview

EXERTHERM INTEGRATION OPTIONS
Max 32 Datacards
Modbus TCP/IP
Max 10 Datacards Modbus TCP/IP
RELAY CONTACTS
Figure 2 Exertherm Integration Options

CORE COMPONENTS
EXERTHERM NON-CONTACT INFRARED (IR) SENSOR
The IR Sensor has been specifically designed for thermal

monitoring. It provides a mV output signal and requires no
external power source, similar to a conventional
thermocouple but is non-contact and requires no amplifier
and has lifetime calibration.
Figure 3 Exertherm IR Sensor
The IR Sensors are small, low cost, ABS plastic, hermetically
sealed to IP67, non-contact devices, which measure the rise above ambient temperature (Delta T).
The IR Sensors are supplied with two ABS nuts for securing the Sensor in the appropriate bracket.
EXERTHERM EM CABLE SENSOR
Designed specifically for the thermal monitoring of LV

cables connected to either the breaker or busbar
connections.
These small, low cost, non-powered Sensors provide mV
output signal which read rise over ambient temperature
(Delta T). Figure 4 Exertherm EM Cable sensor
Sensor housing is a rugged, resin (UL 94 V-O) moulded head incorporating cable stress relief, to
enable fast, easy installation whilst protecting the delicate temperature sensing element.
EXERTHERM CONTACT / AMBIENT SENSOR
Built and designed for thermal monitoring of mainly

mechanical assets, such as bearings, gearboxes and
motors.
They can also be used to measure ambient air

temperature.
Figure 5 Exertherm Contact/Ambient
These sensors provide mV output signal which reads Sensor
absolute temperature, and are housed in a rugged,
resin (UL94 V-O) moulded head incorporating cable stress relief,
to enable fast, easy installation whilst protecting the
delicate temperature sensing element.

EXERTHERM MODBUS DATACARD
The Exertherm Modbus Datacard is a high performance, data

acquisition card for use in the Exertherm 24x7 Thermal
Monitoring System. The Datacards linearise and condition
the signal from up to eight Exertherm Sensors. Processed
information is offered via industry standard RS485 Modbus
RTU protocol.
The Datacard is DIN rail mountable and 24VDC powered,
consuming less than 0.4W. The power wiring allows daisy
chaining to simplify and minimise PSU requirements.
Coloured LED’s mounted on the unit provide indication of the
Datacard health, power status and the Modbus
communications activity.
As standard the Datacard operates at a Baud rate of 9600
(9k6) and 19,200 (19k2). Figure 6 Exertherm Modbus Datacard
ARM XL & LOADMAP

The Exertherm ARM XL device is designed to provide a
complete integral monitoring solution per switchboard,
and is suitable for both new build or retro-fit, while being
entirely vendor neutral (e.g. can be fitted to any
manufacturer’s equipment).
A simple set up, using the pre-configured screens,

provides an easy to use graphical interface to indicate the
status of all Sensors, as well as providing both local and
remote alarms.
Figure 7 Exertherm ARM XL
• Monitors 24x7 up to 80 Exertherm Sensors / 10 Exertherm 8-channel Modbus Datacards for

potentially compromised joints and terminations;
• Uses industry standard Modbus TCP/IP to allow the pass through of the ‘raw temperature
data’ to a host system – enables data to be integrated, trended and stored;
• Protecting circuits operating at a low load with the Patented Exertherm LoadMap solution.
This can adjust the warning alarm level to suit the maximum load that will be applied to a
circuit being thermally monitored (only applicable to the circuits using the 8ch Datacard / IR
EM Sensors).

5. DEFINITIONS
Word Definition
Edgewise means the side dimension (thickness) of the
busbar, positioned with edges facing each other
Flatwise means the width dimension of the busbar,
positioned facing each other
Infrared radiation emitted particularly by heated objects
having a wavelength just greater than that of
the red end of the visible light spectrum, but less
than that of microwaves. The infrared spectrum
that the IR Sensor detects is in the wavelength
5.5 to 20 µm
Node a node is a single 8 channel Exertherm Datacard
device. Nodes can be interconnected to form a
network of cards, each having a unique Node
address
Target / target zone the area of busbar/cable that the Exertherm IR
Sensor is measuring
Joint the point at which the two busbars or cable and
busbar are connected together
Local Ambient the ambient temperature of the air surrounding
the Sensor head and target
LAN Local area network, an IT network which
connects computers and IT equipment within a
limited area such as a school, laboratory or
office building
WAN Wide area network, an IT network that covers a
broad area. One that links across metropolitan,
regional, national or international boundaries
SELV Safe extra low voltage, a circuit whose voltage is
less than 42.4v ac peak or 60v dc max for no
longer than 200ms during normal operation
MCC A motor control centre is an assembly of one or
more enclosed sections having a common
power bus and principally containing motor
control units. Motor control centres are in
modern practice a factory assembly of several
motor starters
LED Light emitting diode, a semiconductor diode
which glows when a voltage is applied
Table 1 Definitions

6. WHERE TO MONITOR
Exertherm can monitor ‘mission critical’ joints, connections and terminations within an electrical
infrastructure.
The typical installations will focus on those areas in which a thermal issue could lead to either
a) downtime or b) a major risk to the safety of people and equipment and c) locations that
historically would have been subject to routine thermal imaging.
SWITCHGEAR / SWITCHBOARDS
The joints monitored in LV and MV switchgear and switchboards would normally include:
❶ ACB Main Incomers, line and load side

❷ Both sides of any bus couplers or tie breakers;
❸ ACB Feeders load side only
4 shipping/transport splits and other critical connections that are made on site.
The IR Sensors can be used to monitor joints associated with all types of air insulated breakers (AIS)
used within typical switchgear.
2 1
3 3 3
Figure 8 Where to Monitor

MCC
NOTE: For thermally monitoring the line/load connections to the individual drawers/buckets
please use the Exertherm MCC Solution (Manual PN# 820201)
TRANSFORMERS
NOTE: For more information please see www.Exertherm.com or contact us via email
support@Exertherm.com

7. INSTALL GUIDE – INFRARED SENSORS

GENERAL ADVICE
A summary of the design advice for the Exertherm IR Sensors is shown in Figure 9 with the following comments…
❶ The IR Sensor must never point upwards.
Never point the Sensor at an upward angle from the horizontal perpendicular.
This could result in the lens becoming covered in a layer of dust; this would reduce the amount of
IR detected from target resulting in a reduced ΔT temperature reading.
❷ The IR Sensor must be positioned in compliance with the minimum clearance distance as stated
by the relevant International, National or Local electrical codes allow. As a guide the Phase-to-
Ground distance is the minimum that should be used for the voltage and insulation of the
busbar/switchboard.
See Section 7.2 Mounting Distances for guidelines.
❸For the best results the target zone should not be directly on the joint, but immediately adjacent
to it.
❹ The optimum viewing angle is perpendicular to the busbar, however IR Sensors will successfully
monitor at any angle up to 45° as shown below.
❸
❶
Figure 9 IR Sensor - Design Advice (Side View)

Figure 10 ❺ shows an ideal location for the IR Sensor to monitor both the busbar to busbar joint,
plus all of the cable connections.
Figure 10 Busbar / Cable Connection
To prevent the local ambient of the Sensor being affected, the Sensors should be
placed in ‘free air’ and not in an area of high temperature airflow. As an example they should not
be placed in the hot airflow found directly above a transformer.
MOUNTING DISTANCES
The IR Sensor used for the continuous thermal monitoring of electrical components is calibrated to
optimise accuracy across a wide range of installation conditions.
A single calibration Sensor is used for a wide range of busbar sizes / mounting distances to target
from sensor face.
The IR Sensor requires a simple gain adjustment which is made in the Datacard Configuration Tool.
The correct gain adjustment can be found by using the IR Sensor Gain Matrix.
To use the matrix, simply cross reference the two measurements to arrive at the correct Sensor gain
adjustment (shown in 22.1).

TARGET ZONE – SENSOR ORIENTATION
The Exertherm IR Sensors are flexible on the mounting orientation provided that the Sensors are
never aimed upwards.
In Figure 11 we see the acceptable locations for monitoring a joint ‘A’:
① these are the optimum locations as they are the closest to the joint they will produce the best
possible results.
② are all acceptable and will deliver good results.
❸ these are not acceptable because it will be necessary for the Sensor to be pointing upwards.
The locations beyond ❹ are too far away from the joint to provide high accuracy monitoring, this
distance is anything beyond 300mm (12 inch).
❺ Avoid the area on a bend where the busbar may have been distorted and any protective
insulation might not be securely fixed to the busbar. We recommend the target area should be the
nearest flat surface as shown ① and ② below.
Figure 11 Possible Sensor Locations

OPTIMUM VIEWING ANGLE
The optimum viewing angle of the IR Sensors is perpendicular to the centre of the busbar (❻ in
Figure 12 & Figure 13).
But it is acceptable to view at up to 45° from the perpendicular targeted at the centre of the busbar,
as shown in ❼ in Figure 12 & Figure 13 subject to always being aimed at the middle of the busbar.
❻ 45°
Figure 12 Viewing Angle – Elevation (side view)
Birds Eye View
45° 45°
❼ ❼
Figure 13 Viewing Angle –Plan (Birds eye view)
Never point the IR Sensor at an upward angle from the horizontal perpendicular.

TARGET ZONE – SURFACE FINISHES

ACCEPTABLE SURFACES…
In order to ensure that the IR Sensor accurately measures the temperature of the surface of the
target busbar the surface of the bare metal busbar must be treated to increase its emissivity to
greater than 0.95 and therefore reduce the impact of any reflected IR.
① paint the surface using a high temperature, stove or BBQ matt black paint;
② tight fitting thermoplastic heat-shrink (Raychem type) regardless of the colour or
③ an ‘epoxy dipped’ busbar.
Figure 14 Acceptable Surfaces

UNACCEPTABLE SURFACES…
The surfaces of the busbar that will not produce acceptable results are:
① bare, unfinished busbar as this has insufficient emissivity;
② loose fitting insulation sleeving;
③ protective ‘boot’ over the joint.
② & ③ are unacceptable because there is an air gap between the busbar and the insulation
material.
As air is a very good thermal insulator this will mean that the surface temperature of the busbar
and the surface of the sleeving will not be the same and so Exertherm will produce inaccurate and
potentially variable results.
② ②
Figure 15 Unacceptable Surfaces

TARGET ZONE - DIMENSIONS

The target area, as shown in Figure 16, must always be at least as deep (A) as it is wide (B). This is
applicable to all acceptable surface finishes as described in 7.4.1.
Figure 16 Painted Target Zone

IR SENSOR MOUNTING OPTIONS
The flexibility of the IR Sensors is such that there are many different options to monitor the busbar
near to a joint.
The following examples show some of the options for monitoring different busbar configurations;
the arrow represents the viewing direction of the IR Sensor.
L1 L2
L3 L4
Figure 17 Sensors mounted outside bars viewing inward
L1 L2
L3 L4
Figure 18 Sensors mounted in-between bars

L1 L2 L3
Figure 19 Sensors mounted at an angle (up to 45°)
L1 L2 L3 L4
Figure 20 Sensors mounted above, pointing down onto the top of bars

L1 L2 L3 L4
Figure 21 Sensors mounted viewing the vertical drops
L1 L1 L3 L3
L2 L2 L4 L4
Figure 22 Sensors mounted outside twin bars viewing inward
L1 L1 L1 L2 L2 L2
L3 L3 L3 L4 L4 L4
Figure 23 Sensors mounted in-between triple bars

IR SENSOR - CABLE LENGTH

Each IR Sensor has a standard cable length of 6 meters (20ft).
Cables can be extended but the specification of the extension cable must match the original
cable Belden 9451.
Cable lengths exceeding 12 meters (40ft) are not recommended.
If cables are to be extended they MUST be soldered together.

Do NOT use terminals or crimped connections for extending cables as this will cause signal loss.
During installation cables MUST be cut to length and suitably dressed back to the Datacard
without unnecessary looping of excess cable.
See Section 12.7.1 for how the IR Sensor cable needs to be prepared for connection to the
Datacard.
Figure 24 IR Sensor Cable Extension

8. BRACKETS
EXERTHERM IR SENSOR SUPPORT BRACKETS
The IR Sensor support brackets are an extremely flexible solution manufactured out of Glastic or of
Acetyl Copolymer, trade name Delrin, plastic, and use non-metallic fittings to suit high voltage
environments. The brackets are non-deforming up to a temperature of 110°C (230°F).
Using this linkable design the brackets offer a huge degree of flexibility to suit the vast majority of
applications.
These brackets should under no circumstances be affixed directly to the busbar on either LV or
MV applications.

9. INSTALL GUIDE - EM CABLE SENSORS
THE EM CABLE SENSOR IS SUITABLE FOR LV CABLES ONLY (UP TO 1KV)

CABLE SENSORS MUST NOT BE INSTALLED EITHER
TEMPORARILY OR PERMANENTLY ON BUSBAR
The EM Cable Sensor cannot be used on multi-core cables, i.e. cables in which more than one
current carrying phase is present.

EM CABLE SENSOR PLACEMENT

1. Place the base of the Sensor head (❶) with the flat surface in contact with the cable
insulation
2. The sensor head should be placed approximately 5cm (2”) down from the lug
3. Then secure a cable tie between the two machined ridges on the Sensor head to secure it
in place.
4. The connecting cable (yellow) should be routed away from the back of the Sensor, take
extra care to ensure that the second temperature element (❷) (ambient Sensor) is kept
away from the cable being measured and ensure it is in the local ambient air.
5. The ambient sensor element in the grey plastic tube (❷) should be kept a minimum
distance of 5cm (2”) from the cable being monitored.
5cm
❶ ❶
❷
❷
≥5cm
Figure 25 EM Cable Sensor Installation

EM CABLE SENSOR TEMPERATURE DROP

Tests have shown that there is a 1°C drop in temperature per 2.5cm (1”) from the faulty
joint/termination.
As an example, EM Cable Sensors placed as shown can monitor multiple cables on a single phase,
but will report a 2°C drop from point (A) and a 4°C drop from point (B)
Figure 26 Cable Sensor temperature drop

EM CABLE SENSOR PLACEMENT – MULTIPLE CABLES

The following examples show recommended EM Cable sensor placement when there are multiple
cables per phase on a connection point. Temperature drop alarm levels as Sec 9.2 are still applicable.
6 CABLES PER PHASE - USE 2 EM CABLE SENSORS
Figure 27 6 cables per phase - use 2 EM Cable sensors
7 CABLES PER PHASE – USE 3 EM CABLE SENSORS
Figure 28 7 cables per phase – use 3 EM Cable Sensors

9 CABLES PER PHASE – USE 3 EM CABLES SENSORS
Figure 29 9 cables per phase - use 3 EM Cable Sensors


EM CABLE SENSOR - CABLE LENGTH

Each EM Cable sensor has a standard cable length of 6 meters (20ft).
cable, UL style 2464. Cable lengths exceeding 12 meters (40ft) are not recommended.

See Section 12.7.2 for how the EM Cable sensor cable needs to be prepared for connection to the
Datacard.
Figure 32 EM Cable Sensor - Cable Extension
EM CABLE INSULATION RATING

The insulation rating of cables on which EM Cable Sensors are to be mounted must be equal to or
greater than the voltage rating of the circuit to be monitored e.g. a 1kV circuit requires, as a
minimum, a cable with an insulation rating of 1kV.
EM Cable Sensors MUST NOT be mounted on cables with an insulation
rating BELOW the voltage rating of the circuit.

10. INSTALL GUIDE – CONTACT/AMBIENT SENSORS

CONTACT/AMBIENT SENSORS MUST NOT BE INSTALLED EITHER
TEMPORARILY OR PERMANENTLY ON BUSBAR
CONTACT/AMBIENT SENSOR PLACEMENT

• The Contact/Ambient Sensor can be positioned on any item that an absolute temperature
measurement is required.
• The Contact/Ambient Sensor can also be used to measure ambient air temperature by
placing the sensor head in free air e.g. not attached to a surface.
• Place the base of the Contact/Ambient sensor with the flat surface in contact with the piece
of equipment, then secure with a cable tie (or suitable adhesive for the application).
• The Contact/Ambient Sensor yellow cable should be routed away from the back of the
Sensor; and secured in compliance with National & Local regulations & guidance for data
cable routing/installation.

CONTACT/AMBIENT SENSOR – CABLE LENGTH

Each Contact/Ambient sensor has a standard cable length of 6 meters (20ft).
cable, Compensation cable UL13 Type PLTC.
Cable lengths exceeding 12 meters (40ft) are not recommended.

See Section 12.7.3 for how the Contact/Ambient Sensor needs to be prepared for connection to
the Datacard.
Figure 33 Contact/Ambient Sensor - Cable Extension

11. CABLE ROUTING

All Sensor cables and containment routes must adhere to all appropriate international, IEC, UL, BS,
ANSI and local standards for clearance from busbars and cables depending on circuit voltages.
If Sensor cables are to be routed through switchgear, they must be kept away from all busbars and
in accordance with good electrical practice and regulations for installation of communication
cables within electrical panels.
The routing of the Sensor cables should start at the Sensor head and then run back to the
Datacard where it should be cut to the required length, dressed, and connected.
The Sensor or the Sensor cable should never be attached to a busbar, even as a temporary
measure.
Sensor & Communication cables should never be installed in containment containing any power
cables, they should be run in compartments designed for signal and communication cables. They
should never be installed parallel with any high voltage or power cables / busbars. If they must
cross any power cables / busbars, then this should be at right angles and with a suitable clearance
to comply with all appropriate standards.
The Sensors themselves are not affected by EMF found within switchgear operating at 50 or 60Hz.
Both the IR Sensors, EM Cable Sensors and Contact/Ambient Sensors have been tested for EMC /
EMF compliance to immunity when connected with the Exertherm Datacard to EN 55024 (1998) +
A1 (2001) + A2 (2003) standards.
IMPORTANT – PLEASE READ

Excess cable MUST be trimmed / removed.
Excess cable must NOT be coiled / looped.
Cable ends MUST be protected by the application of either rubber or heatshrink sleeve;
this is to stop the internal shield cable being able to contact any metallic surface, or other shield
or conductor. (As a last resort a neat wrap of electrical insulation tape can be used instead).

12. EXERTHERM MODBUS DATACARD

This device must NOT be powered from a supply whose voltage exceeds 24VDC ±10%.
Under no circumstance should either a mains direct 120VAC or 240VAC supply be
connected directly to the unit.
This will result in irreversible damage to the unit
and possibly, personnel or other equipment located nearby. The power through
any terminal connection should not exceed 5Amps.
SAFETY AND USE OF EQUIPMENT – EXERTHERM MODBUS DATACARD

It is important that all instructions contained within this manual are adhered to, especially the use
of the equipment as specified by the manufacturer.
The Exertherm Modbus Datacard is part of an overall system and has limits in relation to
environmental conditions, electrical supplies and signal inputs. If this device is used outside of the
set limits as laid down in this manual and not used in a manner as specified by Exertherm then
Exertherm cannot be held responsible for any outcome, direct or indirect consequence, whether to
the Datacard, operator or other equipment or property which arises from this misuse.
The circuitry within this device is protected via automatic fuses and optical isolation from any supply
voltages. If this automatic fuse operates, the datacard will not function and all LED’s would
extinguish. This automatic fuse is of a self-resetting type. As this item is supplied via a SELV supply
i.e. 24VDC whose energy is below 15W, most electrical hazards have been removed; but installation
and maintenance MUST ONLY be carried out by competent and trained personnel in accordance
with all applicable international, national, regional and local regulations and codes.
The Exertherm Modbus Datacard has no on board method of isolating the supply voltage to itself,
so a means of isolation must be provided as below:
• A switch or circuit-breaker shall be included in the building installation.
• It shall be in close proximity to the equipment and within easy reach of the operator.
• It shall be marked as the disconnecting device for the equipment.
An equipment switch or circuit-breaker employed as a disconnecting device shall comply with
relevant requirements of IEC60947-1 and IEC 60947-3.

MODBUS DATACARD
Each Datacard has been pre-addressed in the factory
as Modbus address 247.
They contain no settings other than each input
channel is set at:
• type “No Selection”
• address at 247
• data rate at 9600Kb
• 8 data bits, 1 stop bit, No Parity.
To commission the Datacards a software suite called
“Exertherm Datacard Configuration Tool” must be
used.
This described in detail in Section 14.
Figure 34 Exertherm Datacard Overview

INSTALLATION
The Datacard has a moulded clip which allow for mounting on DIN rails (Top hat rail EN 50022) &
can be positioned vertically or horizontally.
TO MOUNT
Place the top of the

moulded clip onto the DIN rail
Rotate downwards to clip the bottom

edge in place
Figure 35 Mounting a Datacard

TO REMOVE
Disconnect/switch off the Power Supply.
Insert a suitable size flat-blade

screwdriver into the white slot
at the base of Datacard
Then lever this slot

down and rotate the
Datacard upwards and outwards.
This then releases the Datacard
from the rail
Figure 36 Removing a Datacard
RESET SWITCH
FACTORY RESET
The reset switch is on the top of the Datacard on the right-hand side. For factory reset of
communication settings:
• Press & hold the reset switch until ALL LEDs on the front of the Datacard flash TWICE
• Then release the reset switch
• If the LED’s do not flash twice then you will need to try again.
• The device will then reset all its communication parameters to factory default settings, the
programmed Sensor configuration remains unaffected
• If no errors are detected the yellow status LED will pulse, (rather than be lit continuously).
This factory default reset sets the address to 247, baudrate to 9600, No parity, 8 bits and 1 stop bit.
So 247,9600,N,8,1
Now use the Exertherm Datacard Configuration Tool to complete the configuration of the reset
Datacard.

DIAGNOSIS LEDS
Three LEDs on the front of the Datacard provide the user with device status and bus activity
information:
RED LED: Flashing - the Datacard is transmitting data (TX).

GREEN LED: Flashing - the Datacard is receiving data (RX).
YELLOW LED: Pulsing - the system is running in a healthy condition
YELLOW LED: Steady – Datacard is powered and in FAULT (see Section 21.1 for
Troubleshooting advice).
INTERNAL TEMPERATURE SENSOR

The internal temperature sensor is located close to the analogue input terminals. This is only used
for the cold junction compensation when k-type thermocouple sensors are used. This serves no
other purpose.

CONNECTIONS, SENSORS AND POWER SUPPLY

Do NOT connect Sensors to the Datacard when the Datacard is powered.
The Sensor connection terminal block at the base of the data acquisition card has two sets of
terminals one above the other. The input channels are labelled 1 through 8.
We recommend that you use an I/O-list to record the connections of your Sensors and Datacards
and this document is provided in Section 22.2
To connect the Sensor wires a flat blade screwdriver with a maximum blade size of 2.5mm
width should be used.
The Datacard is intended for thermocouple style input signal levels and therefore only signal
levels with a maximum voltage between Ain+ and Ain- of 5VDC can be used.
Signal levels above these could cause irreversible damage to the unit and possibly, personnel or
other equipment located nearby

IR SENSOR CONNECTION TO DATACARD
IR Sensor cable needs to be prepared for connection to the Datacard.

1. Strip 40mm of outer cable insulation from the end of the cable to expose the inner red
and black cores.
2. Then strip 10mm of the inner red and black insulation to expose the bare wire for
connection to the Datacard.
3. Remove the Shield cable.
4. Cable ends MUST be protected by the application of either rubber or heatshrink sleeve;
this is to stop the internal shield cable being able to contact any metallic surface, or
other shield or conductor.
(As a last resort a neat wrap of electrical insulation tape can be used instead).
Red positive Ain+ upper row terminals

Black negative Ain- lower row terminals
The IR Sensor is manufactured with a

screened (shielded) cable type Belden
9451. This is a twisted pair with overall Red+
beldfoil enclosure (shield)
In certain circumstances it has been
found that connecting the shield to an Black-
earth connection, causes a slight offset
on the Sensor reading due to a very
small signal bleed internally within the
thermopile device.
The shield serves no purpose on the
Sensor as the twist of the Sensor cables
alleviates and cancels any noise or IR Sensor
pickup issues which may arise.
Figure 37 IR Sensor Terminations – Connection to Datacard
Therefore, to stop this offset becoming
an issue the IR Sensors should be installed with the shield cable cut and NOT terminated on any
Earth potential.

EM CABLE SENSOR CONNECTION TO DATACARD
EM Cable Sensor cable needs to be prepared for connection to the Datacard.

1. Strip 40mm of outer cable insulation from the end of the cable to expose the inner
brown and white cores.
2. Then strip 10mm of the inner brown and white insulation to expose the bare wire for
3. Remove the Shield cable
Brown positive Ain+ upper row terminals

White negative Ain- lower row terminals
Brown+
White-
EM Cable Sensor
IR SensorSsnreo
Figure 38 EM Cable Sensor Terminations – Connection to

Datacard

CONTACT/AMBIENT SENSOR CONNECTION TO DATACARD
Contact/Ambient Sensor cable needs to be prepared for connection to the Datacard.

1. Strip 40mm of outer cable insulation from the end of the cable to expose the inner
yellow and red cores.
2. Then strip 10mm of the inner yellow and red insulation to expose the bare wire for
3. Remove the Shield cable
Yellow positive Ain+ upper row terminals

Red negative Ain- lower row terminals
Yellow+
Red-
Contact/Ambient
Sensor
Figure 39 Contact/Ambient Sensor Terminations – Connection to

Datacard

POWER CONNECTION TO DATACARD

The 24VDC (+/-10%) power supply
connection terminal blocks on the Datacard
are marked with “+“, “gnd” and “-”.
Both blocks are internally connected; this
way it is possible to bring the power supply to
other Datacards using either set of terminals.
Standard is power in on the left and out on
the right.
Figure 40 Power Supply Terminations – Connection to

Datacard

LINKING DATACARDS
Figure 41 Linking Datacards
Depending on the limitations of the front-end software being used as the graphical user interface,
up to 32 Datacards can be linked together to form a Modbus daisy-chain.
Datacard Patch Cable PIN OUT

At the Datacard side RJ45 Modbus connections are:
Pin 1: RS-485+
Pin 2: RS-485-
Pin 3: RS-485 GND
Pin 6: Shield-GND
Figure 42 Datacard patch cable pin out

Examples of RS232/RS485 adapters that we have
tested are Moxa TCC-100 and Moxa MGate MB3180.
NOTE: If connecting the Datacards to the Exertherm ARM XL (Max 10 Datacards) please refer to
the ARM XL Manual (PN# 820208)

The Datacards are not Ethernet compatible and the RJ45 connection should not be used to
directly connect to a PC/LAN port.
WITHIN A SINGLE ITEM OF EQUIPMENT
In order to connect the Datacards together in a ‘daisy-chain’ use a standard Cat5 (or better) patch
cable between the X0/X1 sockets on one Datacard to the X0/X1 sockets on the next. There is no
difference or priority for which socket should be used.
The last Datacard in the daisy chain should connect from the X0/X1 RJ45 socket to any local front-
end hardware or if necessary, a terminal block so that a Belden 9841 cable can be used to connect
to the front-end equipment.
There are several different pre-manufactured cables which are used for communications between
the Datacards. All of these cables have pre-formed and moulded RJ45 connecting plugs on either
end.
Description
Patch Cable – 0.3m / 1 ft, RJ45 Connectors
Patch Cable – 0.9m / 3 ft, RJ45 Connectors
Patch Cable – 3m / 10 ft, RJ45 Connectors
Table 2 Patch Cables
BETWEEN ITEMS OF EQUIPMENT
If you need to connect Datacards from different switchboards together we recommend that
depending on the overall length of the Modbus chain then either using a patch cable or the end
Datacards in the two pieces of equipment are both brought to a terminal block and the inter-
equipment link is completed with a Belden 9841 cable.

13. PRE-COMMISSIONING PREPARATION

The Exertherm Configuration and Commissioning Kit [part no. 800447] includes the Datacard
Configuration Tool and a commissioning cable; both of which are needed in order to commission
the Exertherm system.
EXERTHERM DATACARD CONFIGURATION TOOL INSTALLATION

The “Exertherm Datacard Configuration Tool” will be delivered on an installation USB.
Minimum requirements of the PC/Laptop:
Windows XP, Vista, Windows 7.0, Windows 8; Windows 10; 1 GB spare hard drive capacity, 1 GB
RAM, 1024x800 Screen resolution and a RS232 Serial communication port or USB port with
converter (Com 1 to 10)
❶ Insert USB into Laptop / PC.

❷ View your USB drive via Windows Explorer
and run the setup program:
❸ Click on “OK” to continue setup:

❹ Please use the specified location for

correct operation of the Config
Tool, and click the Setup icon:
❺ Click “Continue”.
❻ If this screen appears, always click

“Yes”.

❼Click “OK” to finish installation.

14. EXERTHERM DATACARD CONFIGURATION TOOL

MAIN SCREEN
To run the Configuration Tool, select the icon on your desktop. After starting up the program this
screen will be displayed:
C:\Datacard config tool\Config.INI
Figure 43 Config Tool - Main Screen
MENU ITEM SETTINGS:

With the ‘File’ tab function you can open a configuration which has
been previously stored when the “Save Config As” function was used
to store a previous Datacard’s settings.
Configurations will be saved by default in the DATACARD CONFIG
TOOL folder as a *.INI file.

COMMS SETTINGS MENU

The Datacard should be connected with a computer using a standard RS232 to RS485, or USB to
RS485 interface.
Using the Com Settings menu:
1. Select the correct com port on your PC
2. Select the correct baudrate for the Datacard
3. Select the correct parity for the Datacard
All parameters must match exactly with the settings in the Datacard in order to communicate
successfully.
Factory default settings are Datacard address 247, baud rate 9600 (9k6) and No parity.
Please note: The Datacard is capable of operating at various baud rates: 4800 (4k8), 9600 (9k6) and
19200 (19k2).
Figure 44 Config Tool - Communication settings

COMMS ERROR MESSAGE
The following error message as shown in Figure 45 may appear for the following reasons:
Figure 45 Comms Error Message
1. incorrect communication settings have been used,
2. The protocol converter is damaged between the laptop and the Datacard
3. No power to the Datacard
4. The Datacard is damaged, or faulty
Click OK and reselect and correct the communication settings.

COMMISSIONING THE DATACARD

SEARCH NODE:
Always check if the settings from the ‘Com settings’ are appropriate for the Datacards.
There is a search function to find Datacards connected to the system, addresses range from 1 to
247.
1. If the Datacard address is unknown, first enter a start address of 1 and then a stop address
of 247.
2. Or, if the Datacard address is known:

• for example 20, enter a start address below 20, for example 18
• and enter a stop address of a value greater than 20, for example 22.
• Then press ‘Search’ – a progress bar will appear as below

• When the search has successfully finished, online Datacard address will then show in green
as highlighted in Figure 46
• The Device Address in the system parameters portion of the screen will be pre-set with the
found Datacard address.
Figure 46 Config Tool - Search for a Datacard

SYSTEM PARAMETERS:
The Device Address in the system parameters portion of the screen will be pre-set with the found
Datacard address.
To view the parameters of the connected Datacard, click the read button.
The System parameters section allows you to change the communication settings in the Datacard.
After changing any settings:
• Press the “Program” button
• then “Reset” button
• and then Press the “Read” button in order to check for proper programming.
The changes will take effect after resetting or re-powering up the Datacard.
• Device Address With the device address selector you can select either the device to
communicate with or the new address to program into the current connected Datacard
• Baudrate here you can select the required baudrate to program into the Datacard
• Temp unit Option to change the temperature unit of the presented measurements in °C or
°F
• Parity here you can select the required Parity to program into the Datacard
• Serial # and Firmware version shows the current serial number and firmware version
Figure 47 Config Tool - Setting System parameters

CHANNEL CONFIGURATION
From the dropdown, select the correct sensor type for each channel of the Datacard, this must be
carried out to allow the Datacard to display the correct temperature data.
The following Sensor types are available:
• No Selection: Channel Inactive;
• IR.EM-06.SC-DeltaT: for IR EM-06.SC Sensor
• IR-01 Absolute: for IR 01 Absolute Sensor
• Cable EM-DeltaT: for EM Cable Sensor
• Cable Absolute: for Contact/Ambient Sensor
Figure 48 Config Tool - Selecting the Sensor Type

GAIN FACTOR ADJUSTMENT
The only Sensor that utilises the gain factor is the IR.EM-06.SC-DeltaT Sensor.
When selecting the IR.EM-06.SC-DeltaT the gain adjustment window will appear to the right.
The initial value here when selecting IR.EM-06.SC-DeltaT is 1.00.
You MUST amend the relevant ‘gain factor’. It is imperative that the correct value is entered
otherwise values will be inaccurate.
This gain factor is taken from the Exertherm Install & Configuration Record for that Datacard,
which should be provided by the install team.
For your reference a copy is provided in Section 22.1 and 22.2
Gain is not operative until the Datacard is programmed.
Figure 49 Config Tool – IR.EM-06.SC-Delta T Gain Factor Adjustment

PROGRAM DATACARD
Now that all Datacard parameters are complete, they must be programmed into the Datacard.
Ensure the Datacard address in the upper left corner of the screen is correct address you wish to
program.
1. Then press the “Program” button to program the parameters from the PC into the
Datacard.
2. A confirmation message will appear, press OK.
Figure 50 Config Tool - Programming the Datacard

3. Progress bar will move until programming is complete. The TX RX and ACK LEDs will flash
while programming.
4. The Datacard has now been programmed successfully, click OK
5. Then acknowledge the ‘Verify’ message and click OK.
6. Then press the RESET to allow the new parameters to operate.

7. Then press the “Read” button to retrieve the parameters from the connected device to the
PC.
8. Progress bar will move until reading is complete. The TX RX and ACK LEDs will flash while
reading.
9. The Datacard has now been read successfully, click OK.
10. The screen is now populated with the program settings.

11. Now that valid channel types have been programmed, the green status LED will be lit
against the channel name.
If a number of the Datacards are being commissioned on a network then ONLY ONE at a time
can be addressed and setup.
Therefore, all units further down the line either need their power removing or network cables
unplugged.
Once each Datacard is commissioned its network cable can be reconnected and new settings
can be programmed into the next Datacard with address 247.
MONITOR MODE
With the monitor function you can test the configuration of the connected Sensors.
1. Press the “Run” button to start the reading of the Sensors
Figure 51 Config Tool - Monitor Mode

2. Temperature values will appear as shown below
The Sensors will be read every 2 seconds; no other operations can be performed whilst the
monitor is in Run mode.
3. When you are sure that all sensors are functioning correctly, click “Stop” to finish.
Stop MUST be pressed before any other programming functions can take place.
4. This concludes the configuration process and should now be repeated for all Datacards on
the system.

DATACARD CONFIGURATION TOOL SUPPORT

By clicking on the about ‘Help’ button, you can view software version number and build date.
In addition, for help regarding the Exertherm Datacard Config Tool please see the direct links to
either the website or email address which is provided for technical support.
EXERTHERM
Figure 52 Datacard Config Tool Support

15. ALARMS:
The Exertherm Datacards do not provide Alarms, these must be configured in front end systems,
or in the ARM XL HMI if it is included (see separate ARM XL product manual PN# 820208).
SUGGESTED ALARM LEVELS:

It is recommended that 2 alarm levels [warning and critical] are defined.
Based on the accepted standards (NETA Table 10.18 Suggested Actions based on Temperature Rise)
for the monitoring of electrical systems used on Thermographic inspection the following are
suggested alarm points.
Warning Alarm Critical Alarm

IR.EM-06.SC-Delta T ΔT 30C ΔT 40C
IR.EM-06.SC-Delta T (insulated bus) ΔT 20C ΔT 30C
EM Cable-Delta T ΔT 20C ΔT 30C
IR.01 Absolute Client Specific Client Specific
Cable Absolute Client Specific Client Specific
Table 3 Suggested Alarm Levels
Please see Section 9.2 (Cable Sensor Temperature Drop) for further reduction of alarm limits for
multiple cables monitored by a single EM Cable Sensor.

16. MODBUS FUNCTIONS & REGISTERS:
NODE RANGE
The Datacard accepts a node address range of 1…247 which can be programmed by the
configuration software provided.
DETAILS OF MODBUS REGISTERS 001…008
Field values of channel 1 through 8 are contained in 16bit registers. The register values require a
0.1 multiplier to be used when reading via a SCADA system to provide a true temperature reading.
The temperature value can range from -50°C to +300°C depending on the used Sensor. A negative
temp value will be indicated by setting the most significant bit of the 16bit register to 1.
The measurements are updated constantly and can be retrieved using the function codes 03 or 04,
(read input or holding register, both will deliver the same output).
In Modbus terms referred to as 30001….30008 and 40001….40008.
Example: measured ΔT = +2.5°C
1) therefore register content = 25,
2) calculation 25 x 0.1 = ΔT 2.5°C
Example: measured ΔT = - 0.5°C

3) therefore register content = 65530,
4) Invert register and add sign: Xor(65530) x -1 = -5 and;
5) finally calculation -5/10 = ΔT-0.5°C
SIGNED INTEGER
If possible all values in the Register should be read as a ‘signed integer’. Then if the value is read as
a signed integer the signing is carried out automatically by the system reading the registers.

17. ACCEPTANCE TESTING PROCEDURE

In order to test the correct operation of the Exertherm system during the manufacturing, testing,
or commissioning of the equipment. The following test procedure is recommended, using the
Exertherm Verification Device (Part No. 800438).
IR SENSOR TEST PROCEDURE

Once all Datacards have been commissioned and communication established, the Sensors can be
verified for correct operation. This can be carried out either by utilising the “Monitor mode” of the
Datacard configuration software or by utilising the clients own SCADA/BMS system, if connected
and commissioned.
Instructions for the use of the configuration software’s’ “Monitor Mode” are described in Section 0
of this manual.
A stable heat source is required to carry out this testing. The Exertherm Verification Device (EVD),
is a stable black body heat source and has an ambient reference designed for testing the IR Sensors.
It has two machined collars that fit onto the IR Sensors so that each test is carried out to the same
tolerances and conditions.
The device operates from a ‘plug top’ 9 volt dc power supply rather than battery to ensure a steady
temperature reference is obtained.
This testing requires placing the verification heat source onto the end of the IR Sensors.
The user MUST ensure that all bus bars, connections and sources of energy are totally isolated
and locked out to prevent re-energisation prior to any works taking place
If the panel being tested is part of an existing installation, then all connections should
be bonded to earth potential as an extra precaution and also to stop any back feed
from other devices.
At no stage during the testing should the IR Sensor be physically held, or any part of your body
be touching the Sensor, this will cause inaccuracies in the test readings due to elevating the
ambient conditions on the sensor.
Before testing takes place, ensure the Exertherm Verification Device (EVD) has been left in the
same ambient conditions as the IR Sensors for at least 30mins to ensure the ambient block
equalises to local conditions.

EXERTHERM VERIFICATION DEVICE (EVD) INSTRUCTIONS
Follow the stages detailed below to carry out this test procedure: -
1) Plug the power supplies jack style plug into the socket on the end of the verification device.
Figure 53 Power Socket.
2) Plug the power supply into a local 110 / 220 VAC power source. Ensure this is on an extension
lead which can be freely and safely moved around.
3) This verification device has no ‘on/off’ switch so once power is applied the LED will illuminate
‘Red’ to show the device is active. Figure 54 EVD LEDs.
4) The device is ready to operate once the ‘Red’ LED has changed to ‘Green’. This indicates the
heated target has reached 10°C above the ambient target (ΔT10°C). Figure 54 EVD LEDs
5) Place the verification device in front of the IR Sensor to be tested with the IR Sensor fitted
into the white housing in the ‘Ambient’ side all the way to the stop. Figure 55 Ambient
Reading.
6) Hold the verification device in this position without physically handling the IR Sensor for
about three seconds.
7) Note this reading, as displayed in the ‘Monitor mode’ section of the software described in
Section 0
8) Then place the IR Sensor to be tested with the Sensor fitted into the white housing in the
‘Heated’ side all the way to the stop. Figure 56 Heated Reading. Do NOT hold the Sensor in
the heated side for more than 5 seconds.
9) Note this reading, as displayed in the ‘Monitor mode’ section of the software. The difference
between the two readings is now the ΔT (delta T) value and should be in the range of 6°C to
12°C. (This is a wide variance as the Datacard has had its ‘gain’ adjustment added to allow
for a wide range of busbar sizes and mounting distances and this test is carried out at a fixed
distance)
10) Table 4 IR Sensor Verification Values below, identifies the expected values. This is based
on ideal conditions and may differ slightly.
11) This now proves the IR Sensor is reading a correct value as a ΔT (delta T) and is a more
accurate and quicker method than using a heated target and having to either guess or read
an ambient locally with a separate instrument.
Steps 5 to 9 can be repeated a couple of times to double check and prove the Sensors are operating
correctly. Repeat this test for all IR Sensors which are to be verified and note all the readings.

Power socket
Figure 53 Power Socket
Power On (Red LED)
Heated & ready for

use (Green LED)
Figure 54 EVD LEDs
Ambient & Heated

target areas
Figure 55 Ambient Reading Figure 56 Heated Reading

PLEASE NOTE THAT THESE READINGS ARE ΔT, (RISE OVER AMBIENT) AND NOT ABSOLUTE.
THEREFORE 0°C ΔT = 0°F ΔT NOT 32°F P ΔT F
F
o i
i
w g
• The Exertherm Verification Device (EVD) MUST be left to acclimatise g
e 4 in the same conditions as
the IR Sensors for at least 30 mins prior to any testing takingr place. 4
. If the device is moved
between extremes of temperature even as low as a difference .
s of52° to 3°C it will have an effect
o
on the reading and must be allowed to reach its calibrated Delta Temperature. This will be 3
shown by the coloured LED changing state from Green to Red. c
• The verification device has a steady state temperature of Deltak Temperature of 10°C (18°F)
over the local ambient target. e
• It is imperative that the Sensor is both not touched during thet testing by hand or the test unit
is held in position on the Sensor for more than 5 seconds. If this happens it will cause an
internal heating of the Sensor and inaccuracies in the results.
• If the Sensors read within ± 3°C (5.4°F) of 9°C (16.2°F) then they have successfully passed
operational verification.
IR SENSOR PASS/FAIL CRITERIA
If when tested using the verification device the IR Sensors read within the following ranges then they
have successfully passed operational verification.
Calibration Type Min Temp Max Temp

Exertherm IR Sensor 6°C 12°C
Table 4 IR Sensor Verification Values
EM CABLE SENSOR TEST PROCEDURE
Once all Datacards have been commissioned and communication established, the EM Cable sensors
can be verified for correct operation. This can be carried out either by utilising the “Monitor mode”
of the Datacard configuration tool or by utilising the clients own SCADA/BMS system, if connected
and commissioned.
Instructions for the use of the configuration tools’ “Monitor Mode” are described in Section 0 of
this manual.
For the EM cable sensors, a stable heat source is not available as they are in direct contact with the
cable insulation and or local ambient surface i.e. a panel section. Direct heating using heat gun or
similar source is not recommended as this will cause damage to the sensor and or surface they are
attached to. Therefore, the most reliable heat source is the human hand.

This testing requires physically holding or placing your hand on or around the sensors.
The user MUST ensure that all bus bars, connections, and sources of energy are totally isolated
and locked out to prevent re-energisation prior to any works taking place.
If the panel being tested is part of an existing installation, then all connections should
be bonded to earth potential as an extra precaution and also to stop any back feed
from other devices.
At no stage during the testing should the EM Cable sensor head and the ambient grey tube be
held at the same time, this will cause inaccuracies in the test readings due to elevating the
ambient conditions on the sensor.
EM CABLE SENSOR TESTING INSTRUCTIONS
Follow the stages detailed below to carry out this test procedure: -
1) Utilising either the Exertherm Configuration tool or the local SCADA system, note the reading
of the sensors under test.
2) For the EM Cable Sensor, place your hand around or over the sensor head. Try to make as
good a contact as possible.
3) Hold your hand on the sensor for at least 20 seconds.
4) The sensor will take 10 seconds or so to react, note the reading on the configuration tool or
SCADA for this sensor.
5) Body temperature is around the region of 37°C (98.6°F) so should cause a rise in sensor
reading.
6) The sensor should rise positive, if so then the sensor is terminated correctly. If the sensor
reading was to fall negative, then this shows an incorrect and reversed termination at the
Datacard and will need correcting.
7) Note that under normal conditions, as the sensor reads Delta T i.e. the difference between
the sensor head and the ambient tube, the output would be around the 0°C mark ±2°C so
incorrect termination would not be seen. Only when the sensor head is heated will a rise be
seen if the sensor has been terminated correctly as per section 12.7.2 of this manual.
8) All this data must be recorded on the Exertherm Install & Configuration Record sheet which
is supplied in section 22.2 of this manual.
9) For testing the Contact Ambient sensor please follow the same steps 1 through 6. This
sensor is an absolute temperature reading and therefore shows actual temperature within
the enclosure and not a Delta T reading.

10) Again, the data from the Contact Ambient sensor should be recorded on the Exertherm
Install & Configuration Record sheet which is supplied in section 22.2 of this manual.
11) This now proves the EM Cable sensor is reading a correct value as a ΔT (Delta T) and also
that the Contact Ambient sensor is reading a correct value as an Absolute.
PLEASE NOTE THAT THE EM CABLE SENSORS READINGS ARE ΔT, (RISE OVER AMBIENT) AND NOT
ABSOLUTE. THEREFORE 0°C ΔT = 0°F ΔTPNOT F32°F ΔT
F
o i
i
w g
g
e 4
4
r .
s
.
5
o 3
c
k
e
t

18. HIPOT TESTING

OUTLINE
The purpose of this document is to detail the steps and precautions to be taken when carrying out
this kind of test on a piece of switchgear when the Exertherm System has been installed.
The method detailed here must be adhered to otherwise damage to either Sensors or Datacards
and processor devices will result. This will invalidate the warranty on those particular items and
replacement costs will be the responsibility of the OEM or company carrying out the testing.
DESIGN CHECKLIST
The following MUST be adhered to in all cases, with no exceptions
All Sensor distance from busbar locations MUST adhere to all UL, IEC and ANSI standards for
clearance from busbars and cables depending on circuit voltages.
All Sensors cables and containment routes MUST adhere to all UL, IEC and ANSI standards for
clearance from busbars and cables depending on circuit voltages.
If Sensor cables are to be routed through switchgear they MUST be kept away from all busbars
and in accordance with good electrical practice and regulations for installation of
communication cables within electrical panels.
These cables should be never be installed in containment containing any power cables; they
should be run in compartments designed for signal and communication cables.
They should never be installed parallel with any high voltage or power cables /
busbars. If they must cross any busbars then this should be at right angles and with a
suitable clearance to comply with UL, IEC and ANSI clearance standards.
Sensor and all other communication cables must not be run within 150mm (6”) of 13kV circuits.
If circuit voltage exceeds this then clearance must be greater and comply with the previous
standard i.e. UL, IEC and ANSI
Where high electromagnetic fields could be or are present, all Sensor and communication
cables passing through switchgear will be installed as per the previous comment above, i.e.
must be kept a minimum of 150mm (6”) distance from 13kV.
If circuit voltage exceeds this then clearance must be greater and comply with the previous
standard i.e. UL, IEC and ANSI. The Sensors themselves are not affected by EMF found within
switchgear operating at 50 or 60Hz.

DATACARD CONNECTIONS
SENSOR CONNECTION TO DATACARD
This device is intended for thermocouple style input signal levels and therefore only signal levels
with a maximum voltage with respect to shield or between Ain+ and Ain- of 5VDC can be used.
Signal levels above these could cause irreversible damage to the unit and possibly, personnel or
other equipment located nearby
Under no circumstance must a ‘Megger or Hipot’ test be carried out on the Datacard.
POWER CONNECTION TO DATACARD
This device must NOT be powered from a supply whose voltage exceeds 24VDC ±10%.
This includes mains direct 120VAC or 240VAC supply be connected directly to the unit.
This will result in irreversible damage to the unit and possibly, personnel or other equipment
located nearby. The power through any terminal connection should not exceed 5Amps.
Under no circumstance must a ‘Megger or Hipot’ test be carried out on the Power supply or
Datacard.
TESTING PROCEDURE
The following MUST be adhered to in all cases, with no exceptions. Any damage arising from not
adhering to and not following these instructions will invalidate all warranties.
All Sensor cables MUST be routed away from and not in contact with any bar or conductors of
any description.
All Sensors cables MUST NOT have their shield cables connected. Cable ends MUST be
protected by the application of either rubber sleeve or heatshrink sleeve to stop the internal
shield cable being able to contact any metallic surface or other shield or conductor.

All power supply units MUST be totally isolated from any supply by removal of all fuses.
Totally isolate
from any source
Figure 57 HiPot Testing – Power Supply Isolation
All datacards and power supplies MUST have all earth / ground connections removed from
the terminal on both Shield and main power terminations.
Disconnect
GND terminals
Figure 58 HiPot Testing – Disconnect GND

terminals
All Communication cables MUST be removed from any third party device or meter that is
connected to the datacards
If the final link on communications to either terminals or a third party device utilises a
‘Shield’ or ‘Gnd / Earth’ connection then this MUST be removed from the datacard it is
connected to. Disconnect the patch lead from the datacard.
Any Sensor which is mounted in contravention to all UL, IEC and ANSI standards for
clearance from busbars and cables depending on circuit voltages, MUST be disconnected
from the datacard prior to any testing taking place.
All connections MUST be totally removed from the Exertherm ARM XL. This includes,
power supply, LAN Ethernet cables and Modbus RS485 communication cables.

Figure 59 HiPot Testing - Exertherm System Isolation
SCADA / BMS
ARML XL OR

19. TYPE TESTING / DESIGN VERIFICATION

PURPOSE
The purpose of this document is to detail the test method to be used by the OEM or any other
organisation when carrying out “design validation” / proof of concept testing on Exertherm product.
The method detailed here must be adhered to otherwise test results cannot be guaranteed as an
accurate representation of the systems capabilities.
It is essential the installation and configuration of Exertherm product is carried out in
accordance with the contents of this manual.
12) All sensor distance from busbar locations must adhere to all international and local
standards for clearance from bus bars and cables depending on circuit voltages.
13) Testing must be carried out in a location which provides reasonably stable ambient
conditions, i.e. avoid rooms where direct sunlight cannot be prevented, or which are subject
to frequent ambient variances.
14) Ambient temperature will be measured on the Exertherm Sensors i.e. at the lens end of the
IRT/c using any suitably calibrated non-contact temperature measuring instrument with
certified accuracy. Calibration certificate must be available for scrutiny and up to date.
15) The following method of ambient measurement will also be adopted if required and
complies with UL and IEC standards: extract from standards below:
i. …UL uses IEC Standards to investigate both low and medium voltage switchgear. The
following is the requirement for ambient temperature measurement during the
Temperature Test.
ii. …Ambient air temperature limits: Tests may be made at any ambient air temperature
between 10°C and 40°C.
iii. …Measurement of ambient air temperature: Indoor ambient air temperatures shall be
determined by taking the average of the readings of three temperature-measuring
devices, such as thermometers or thermocouples, placed as follows:
a) One level with the top of the structure
b) One 30 cm above the bottom of the structure
c) One midway between the two positions a) and b).
iv. …All temperature-measuring devices shall be placed 30 cm from the structure, not in
front of ventilators, and in locations unaffected by drafts caused by the structure or
appreciable radiation from the equipment. When the ambient air temperature is
subject to variations that might result in errors in measuring the temperature rise, the
temperature-measuring devices should be immersed in a suitable liquid, such as oil in a
suitable container, or reliably attached to a suitable mass of metal.
v. NOTE - A convenient form for such a container consists of a metal cylinder with a hole
drilled partly through it. This is filled with liquid and the temperature-measuring device
is placed therein. The size of the container should be at least 2.5 cm in diameter and 5.0
cm high.

16) The ambient temperature used when calculating the connection Delta temperature will be
the local ambient recorded at the Exertherm Sensor location.
17) All Datacard power supplies will be maintained at 24VDC ±10%.
18) All equipment test apparatus and Sensors to be used during these tests will be left to
acclimatise in the switchgear for a period of a minimum of 1 hour prior to any tests taking
place.
19) This document assumes all Datacards are programmed and commissioned as the relevant
instructions in this Manual.
PROCEDURE: INITIALLY ELECTRICAL CIRCUITS UNDER TEST NOT ENERGISED

1) Ensure all power supplies are set at the correct voltage and within specification i.e. at 24vdc
±10%.
2) Take a reading of room ambient as described in the previous section and note this value on
the test check sheet OEM Design Validation Test Record (section Room Ambient)
3) Take a reading of the ambient temperature at the Sensor under test and note this value on
the test check sheet OEM Design Validation Test Record (section Ambient Test Reading)
4) Take a reading from the Datacard software on the Sensor under test and note the value on
the test check sheet OEM Design Validation Test Record (section Sensor Reading Under Test)
5) Take a reading of absolute temperature from the busbar with a suitably calibrated and
certified temperature measurement device and note this reading. This should be an average
reading across the connection point and not just one ‘spot’ temperature and note the value
on the test check sheet OEM Design Validation Test Record (section Absolute Reading At
Sensor)
6) Subtraction of the ambient (at the sensor) from the connection temperature will result in
the Delta T value and note the value on the test check sheet OEM Design Validation Test
Record (section Calculated Delta T Reading). This should agree with the IR Sensor reading
±3°C (5.4°F)
7) Note all these readings for future reference.
Repeat these steps 3 to 7 for all Sensors in the panel.

All these readings should produce a Delta T value of between -3°C (-5.4°F) to +3°C (+5.4°F)
It should be noted that this is not process control and therefore readings will not be exact to the
degree. The Exertherm Sensor is 100% repeatable in identical conditions.
PROCEDURE: WITH ELECTRICAL CIRCUITS UNDER TEST ENERGISED.

1) With the gear energised and running in test conditions and under test currents and loading,
allow all temperature and ambient to become stable. Leave all equipment to again
acclimatise to local conditions for a minimum of 30 minutes.
2) Ensure all power supplies are set at the correct voltage and within specification i.e. at 24VDC
±10%.
3) Take a reading of room ambient as described in the previous section and note this value on
the test check sheet OEM Design Validation Test Record (section Room Ambient)

4) Take a reading of the ambient temperature at the Sensor under test and note this value on
the test check sheet OEM Design Validation Test Record (section Ambient Test Reading)
5) Take a reading from the Datacard software on the Sensor under test and note the value on
the test check sheet OEM Design Validation Test Record (section Sensor Reading Under Test)
6) Take a reading of absolute temperature from the busbar with a suitably calibrated and
certified temperature measurement device and note this reading. This should be an average
reading across the connection point and not just one ‘spot’ temperature and note the value
on the test check sheet OEM Design Validation Test Record (section Absolute Reading At
Sensor)
7) Subtraction of the ambient (at the sensor) from the connection temperature will result in
the Delta T value and note the value on the test check sheet OEM Design Validation Test
Record (section Calculated Delta T Reading). This should agree with the Exertherm IRT/c
sensor reading ±3°C (5.4°F)
8) Note all these readings for future reference.
Repeat these steps 4 to 7 for all Sensors in the panel.

All these readings should produce a Delta T value of between -3°C (-5.4°F) to +3°C (+5.4°F).
The results should be compared to the relevant data sheet for the Sensor’s tolerances in terms of
accuracy and repeatability.

20. ROUTINE MAINTENANCE

GENERAL
The Exertherm system requires no routine maintenance.

21. TROUBLESHOOTING
DATACARD TROUBLESHOOTING GUIDE
When the LEDs are sequentially flashing (R-G-Y-R-G-Y...) the module has detected a failure during
its self-test procedure.
One of 4 errors may exist:
1) Cannot establish Comms – replace any cables or converters with Exertherm product (PN#
800447)
2) Node address out of range, reset to factory stored values (see Factory reset).
3) Under or over voltage of power supply, check power to connections.
4) Module not programmed/initialized, return factory values (see Factory reset).
If after carrying out these troubleshooting steps, the device is still not functioning and the LED’s are
still sequentially flashing (R-G-Y-R-G-Y...). Then the Datacard must be returned for testing and
replacement (under warranty if applicable).
After powering up the module all 3 LEDs will light up shortly indicating the self-test procedure.
It will also allow the user to check the proper operation of the LEDs.
After this start-up sequence the yellow LED should pulse indicating proper operation mode.





22. TECHNICAL DATASHEETS

DATA SHEET – IR SENSOR GAIN MATRIX

EXERTHERM INSTALL & CONFIGURATION RECORD
Project Name:
Customer:
Section Ref:
Modbus Address: Serial No.:
DATACARD CHANNELS
C C C C C C C C
H H H H H H H H
A A A A A A A A
N N N N N N N N
N N N N N N N N
E E E E E E E E
L L L L L L L L
1 2 3 4 5 6 7 8
Section Reference
Phase Reference
Sensor Type
No Sensor
IR.EM-06.SC – Delta T
IR-01 Absolute
Cable EM – Delta T
Cable – Absolute
IR.EM-06.SC Only
Busbar Size
Mounting Distance
Gain Factor Used
Factory Acceptance Test
Initial Value
Heat Tested Reading
Datacard FAT: Accepted / Signed

Installer: Client Rep.
Date: Date:
Sign: Sign:


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820008

Exertherm® Design, Installation

1. VERSION CHANGE CONTROL RECORD

THIS IS A CONTROLLED DOCUMENT:

Page 2 of 89 ©Exertherm 2022 MA-141-1-EN

2. USING THIS MANUAL

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Modbus Datacard ............................................................................................................................................................... 41

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FIGURE 44 CONFIG TOOL - COMMUNICATION SETTINGS .................................................................................................................................... 55

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3. OWNERSHIP, NOTES AND CRITICAL DISCLAIMERS

INTELLECTUAL PROPERTY, PATENTS, TRADE MARKS AND REGISTERED DESIGNS

Page 8 of 89 ©Exertherm 2022 MA-141-1-EN

STANDARDS AND APPROVALS

PERSONNEL QUALIFICATION AND TRAINING

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Page 10 of 89 ©Exertherm 2022 MA-141-1-EN

Figure 1 Exertherm System Overview

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EXERTHERM INTEGRATION OPTIONS

Max 10 Datacards Modbus TCP/IP

Figure 2 Exertherm Integration Options

Page 12 of 89 ©Exertherm 2022 MA-141-1-EN

The IR Sensor has been specifically designed for thermal

EXERTHERM EM CABLE SENSOR

Designed specifically for the thermal monitoring of LV

EXERTHERM CONTACT / AMBIENT SENSOR

Built and designed for thermal monitoring of mainly

They can also be used to measure ambient air

Page 13 of 89 ©Exertherm 2022 MA-141-1-EN

EXERTHERM MODBUS DATACARD

The Exertherm Modbus Datacard is a high performance, data

ARM XL & LOADMAP

A simple set up, using the pre-configured screens,

• Monitors 24x7 up to 80 Exertherm Sensors / 10 Exertherm 8-channel Modbus Datacards for

Page 14 of 89 ©Exertherm 2022 MA-141-1-EN

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❶ ACB Main Incomers, line and load side

Figure 8 Where to Monitor

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7. INSTALL GUIDE – INFRARED SENSORS

Figure 9 IR Sensor - Design Advice (Side View)

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Figure 10 Busbar / Cable Connection

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TARGET ZONE – SENSOR ORIENTATION

Figure 11 Possible Sensor Locations

Page 20 of 89 ©Exertherm 2022 MA-141-1-EN

OPTIMUM VIEWING ANGLE

Figure 12 Viewing Angle – Elevation (side view)

Birds Eye View

Figure 13 Viewing Angle –Plan (Birds eye view)

Page 21 of 89 ©Exertherm 2022 MA-141-1-EN

TARGET ZONE – SURFACE FINISHES

Figure 14 Acceptable Surfaces

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Figure 15 Unacceptable Surfaces

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TARGET ZONE - DIMENSIONS

Figure 16 Painted Target Zone