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XYR5000 Wireless Instrumentation Tech Note: Experion PKS® Modbus RTU Integration Issued: October, 2004 MODBUS Integration Overview The Wireless Transmitter integration to Honeywell TPS (PM, HPM, xPM) or Experion PKS is by Modbus RTU into a Serial Interface Module (SIM). Each wireless transmitter will require 10 "Little Endian Byte Swapped" 32 Bit floating-point format registers to provide both transmitter PVs' and Alarm functions to the host system. Each XYR5000 Base Radio will require 10 16-bit numeric. There are 2 methods of assigning Modbus addresses to each base station and associated transmitter(s): "Device Mode" or "Register Mode". The default "Device Mode", assigns a separate Modbus node number to each wireless transmitter. This mode is easy to use (except that the Modbus node address equals the transmitter ID 1 plus 1), but is very limiting because the SIM only accommodates 16 slave devices, or in other words 16 transmitters when using this mode. We therefore recommend using "REGMODE" (under RS-485 -> MODMAP) for all integrations. In this mode a single Modbus 03 command can be used to communicate to all the transmitters connected to one base radio. As a result a maximum of 16 base radios, with multiple transmitters each, can be interfaced to a single SIM-FTA. Please note that in REGMODE, each transmitter is given a block of 10 registers in the base unit's contiguous memory space for accessing its data (e.g. status values, primary & secondary PVs', etc). The maximum number of wireless transmitters that can be integrated to the Experion PKS is determined by the speed of controller module and the mix of inputs. The c200 controller operating at 50 msec can support three (3) SIM modules. The C200 controller operating at 5 msec can support only one (1) SIM. Each SIM module can support two SIM-FTA’s. Each SIM-FTA can support a maximum of 48 wireless transmitters with five (5) floating point each. One array is needed to read in the Base Radio status (integer) Therefore, the theoretical maximum number of congruent wireless transmitters that can be supported by Experion PKS operating at 50 msec: 3 SIM’s x 2 SIM-FTA x 16 array slots x 3 transmitters = 288 transmitters per C200 controller Note: The Wireless solution is intended for monitoring and/or SCADA applications.
Refer to the XYR5000 Wireless Base Radio User Manual for a more complete description of the Modbus configuration parameters used in this document.
Honeywell XYR5000 Tech Note HONEYWELL CONFIDENTIAL & PROPRIETARY This work contains valuable, confidential, and proprietary information. Disclosure, use, or reproduction outside of Honeywell Inc. is prohibited except as authorized in writing. The laws of the United States and other countries protect this unpublished work. DO NOT DISTRIBUTE THIS DOCUMENT TO ANYONE OUTSIDE OF HONEYWELL.
M O D B U S F TA I n s t a l l a t i o n
Overall Modbus Interface Connections (Refer to
Figure 1 shows the typical component connections associated with a Modbus Field Termination Assembly (FTA) installation for reference.
Figure 1 Modbus Serial Interface connections
Mounting Modbus FTA
The Modbus FTA can be mounted on a standard FTA Mounting Channel, DIN rail (35 x 7.5 mm top hat rail), or surface mounted on a wall. The FTA is designed for mounting in a cabinet or in a controlled environment. Do not expose the FTA to the weather. The FTA has a mounting hole in each corner. To mount on a DIN rail, you must attach the DIN rail adapter to the bottom of the FTA, using the hardware supplied. Otherwise, mount the FTA on Mounting Channel standoffs or drill holes and use screws and non-metallic spacers to attach the FTA to a wall. Be sure the FTA is grounded either directly or through the mounting means.
EXperion PKS Integration.doc Honeywell Page 2 of 15
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Wiring Modbus FTA to Power Adapter
Use the procedure in the following table to wire the Modbus FTA to the Power Adapter.
Step Action 1 Is the Modbus FTA mounted in a cabinet with the Power
Adapter? Yes, be sure you have the appropriate number and length of Honeywell internal cable MU-KLAMxx on hand. Go to the next Step.
No, be sure you have the appropriate number and length of Honeywell external cable MU-KSXxxx on hand. Go to the next Step.
(Note: Cable must have 2 individually shielded, twisted pairs)
2 On one twisted pair mark one lead P- and the other P+ at both ends of the cable. On the other twisted pair mark one lead S- and the other S+ at both ends of the cable. Repeat this for other cables, as applicable.
3 Locate the J2 (CHANNEL A), 6-pin connector on the Power Adapter. Observing polarity, connect the cable lead marked P- to pin 1 - PWR CUR and lead marked P+ to pin 2 + PWR CUR. Connect the shield wire for this pair to pin 3 SHD. Observing polarity, connect the cable lead marked S- to pin 4 - SER and lead marked S+ to pin 5 + SER. Connect the shield wire for this pair to pin 6 SHD. See the connection diagram in Figure 2 for reference. (Note that the shield wires are connected to ground at the Power Adapter end only.)
4 Locate the J1, 4-pin connector on the FTA "A". Observing polarity, connect the cable lead marked P- to pin 1 - PWR CUR and lead marked P+ to pin 2 + PWR CUR. Trim the shield wire for this pair close to the cable insulation. Observing polarity, connect the cable lead marked S- to pin 3 - SER and lead marked S+ to pin 4 + SER. Trim the shield wire for this pair close to the cable insulation. See the connection diagram in Figure 2 for reference.
5 Do you have a second FTA to be connected to the Power Adapter?
Yes, continue with Step 6.
No, exit this procedure and go to the next section Wiring Modbus FTA to Modbus devices.
6 Locate the J3 (CHANNEL B), 6-pin connector on the Power Adapter. Observing polarity, connect the cable lead marked P- to pin 1 - PWR CUR and lead marked P+ to pin 2 + PWR CUR. Connect the shield wire for this pair to pin 3 SHD. Observing polarity, connect the cable lead marked S- to pin 4 - SER and lead marked S+ to pin 5 + SER. Connect the shield wire for this pair to pin 6 SHD. See the connection diagram in Figure 2 for reference. (Note: Shield wires should be connected to ground at the Power Adapter end only)
7 Locate the J1, 4-pin connector on the FTA "B". Observing polarity, connect the cable lead marked P- to pin 1 - PWR CUR and lead marked P+ to pin 2 + PWR CUR. Trim the shield wire for this pair close to the cable insulation. Observing polarity, connect the cable lead marked S- to pin 3 - SER and lead marked S+ to pin 4 + SER. Trim the shield wire for this pair close to the cable insulation. See the connection diagram in Figure 2 for reference.
8 Go to the next section Wiring Modbus FTA to Modbus devices.
Figure 2 Power Adapter to Serial Interface FTA Wiring
EXperion PKS Integration.doc Honeywell Page 4 of 15
Wiring Modbus FTA to Modbus Devices
Making EIA-232 (RS-232) connections You will need a null modem cable with a 25-pin, male connector to connect the EIA-232 Modbus device to the J2, DB-25 type connector on the FTA. Use the J2 connector pinout data in Figure 3 to construct the EIA-232 interface cable. Since individual Modbus device connections may vary, be sure to modify the common EIA-232 pin outs shown in Figure 3, so that the FTA Transmit Data pin (2) connects to the Modbus device Receive Data pin and the FTA Receive Data pin (3) connects to the Modbus device Transmit Data pin. Be sure the length of the EIA-232 interface cable does not exceed 15 meters (50 ft).
Figure 3 Pins common to RS-232 25-pin connector and FTA J2, DB-25 type connector.
Making EIA-422/485 connections You will need appropriate cable, such as Belden Corporation Type 9271 Industrial Twinax, to connect up to 15 EIA-422/485 Modbus devices in multidrop fashion to the J3, 5-pin connector on the FTA. Use the connection details shown in Figure 5 and the following guidelines to configure a multidrop EIA-422/485 interface. The recommended maximum length for the interface cable is 300 meters (1000 ft). However, this can be extended up to 1220 meters (4000 ft) with the appropriate cable (Belden type 9182). Please consult with Honeywell Technical Assistance for the recommended cable. To avoid potential ground loops, connect the shield for the interface cable to ground at the FTA end only. See Figure 4 for wiring details. To minimize signal reflections, connect a 120 Ω, ±10%, ½ Watt resistor across J3 pins 1 and 5 and across the Data (+) and Data (-) terminals on the last device in the link. (Note: the resistor value may be different based on the requirements of the actual cable used.) The FTA includes two (2) ¼ Ampere fuses (F1 and F2) to protect it from excessive current draw on the data lines.
EXperion PKS Integration.doc Honeywell Page 5 of 15
Figure 4 Modbus FTA EIA-422/485 connections.
Configuring Wireless Transmitter Inputs on Experion PKS or Plantscape 1. Select the block SINUMARRCH (SI Numeric Array) and drag it into a new Control Module.
Fig. 5 SINNUMRRCH Selection
EXperion PKS Integration.doc Honeywell Page 6 of 15
Open the SINUMARRCHA module and rename it.
Fig. 6 SINNUMRRCH Block 2. Select the correct SI module and assign the channel to an available slot. Ex. 0-15 for FTA01 & 16-
31 for FTA02.
Fig 7 Configuring SINNUMRRCH 3. Fill in the serial link device address.
• This would be the base station address.
4. Enter the Starting Element Index. • This would be the first valid transmitter memory location.
5. Enter the Number of Numeric Values.
• This would be last transmitter memory location.
6. Leave Write option = WRITEONDIFF • (This option does not apply to Experion PKS)
EXperion PKS Integration.doc Honeywell Page 7 of 15
Fig 8 Configuring SINNUMRRCH 7. Fill in the AUXDATA[0] through AUXDATA[3] as per the table below. Examples are: AUXDATA[0] NaN Leave as NaN AUXDATA[1] NaN Default value of 1.5 seconds for retries AUXDATA[2] 232.0 RS232 no modem control AUXDATA[3] 9600.0 9,600 Baud Rate with no parity bit
AUXDATA[0] Specifies the Keep Alive Address for a Modbus coil.
Note: not applicable to the XYR-5000
This parameter tells the Modbus system that the Experion PKS subsystem is functioning. It can be configured separately on each array channel block, but no two-array channel blocks should write to the same coil. The coil address must be within the range 00001 to 09999. Note: When this parameter is NaN, the Keep Alive function is inactive. If you want to check the Keep Alive coil, you must program the Modbus device to do so.
AUXDATA[1] Specifies the time interval in seconds to wait before attempting a message retry.
If a valid response is not received after three tries (original plus two retires), a MSGTMOUT error results. The range is 0.25 to 5 seconds on NaN. If NaN is specified, the default timeout is 1.5 seconds. A timeout value can be configured separately for each array channel block.
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AUXDATA[2] Specifies the signaling protocol and modem control in an integer/decimal format: mmm.n Where mmm is the signaling protocol and n is the modem control (0 = OFF and 1 = ON). For example, 232.1 indicates EIA-232 with modem control ON. The other choices are 232.0 and 485.0. EIA-232 permits use of an external modem.
The first valid array channel block loaded to the Controller with values in AUXDATA[2] and AUXDATA[3] sets the mode and baud rate for the FTA communications. This means that AUXDATA[2] AUXDATA[3] must contain the same value for all array blocks configured through the same FTA. If array blocks loaded later to that FTA have different AUXDATA[2]/[3] values, an AUXMATCH error results. The modem control feature switches the following signals: RTS, CTS, DSR, DTR, and DCD. When AUXDATA[2] is NaN, the protocol is EIA-232 and modem control is OFF.
AUXDATA[3] Specifies the baud rate in an integer/decimal format: bbbbb.n Where bbbbb is the Baud Rate and n is the Parity (0 = None, 1 = Odd, 2 = Even).
The legal baud rates are 19200, 9600, 4800, 2400, and 1200. NaN (dashes) results in a default value of 19200 baud with odd parity.
AUXDATA[4] to AUXDATA[7]
These parameters are not applicable to a Generic Modbus interface.
Set these parameters to NaN when communicating with a Modbus.
STARTINDEX and number of elements parameters configuration:
The value configured for the STARTINDEX parameter in a given Array Channel block determines the Modbus Start Index and function. Only one type of external data can be accessed per Array Channel block. The number of elements parameter (NNUMERIC) Numeric Array block determines the number of numerics’ in a given data array. The following table shows the relationship between Modbus functions and the STARTINDEX and number of elements parameters. The Start Index Ranges defines the Modbus address map. The most significant digit in this column identifies the Modbus function (for example,). The lower four digits define the starting address to access data for the given Modbus function. The address ranges 2xxxx, 8xxxx instruct the SI firmware of the type of data to expect.
The maximum number of elements specifies the maximum number of numerics that can be configured for a given Start Index Range and block type. All of the specified elements are read in a single transaction.
EXperion PKS Integration.doc Honeywell Page 10 of 15
Start Index Ranges
Modbus Function
Array Channel Function Block
Data Range
Maximum Number Of Elements
20011 to 29999*
03 – Read Holding Registers SINUMARRCH
Word Swapped IEEE Floating Point Read/Write
-34e38 to +34e38
16
90001 to 90010
03 - Read Holding Registers
16 bit Un-signed Integers 0 - 65535 32
* The Starting Index (NNSTIX) for a wireless transmitter is calculated as Tx #(N) times 10 plus 20001. The number of numeric (NNUMERIC) for each transmitter is 5. These 5 numerics are made up of 10 Modbus registers, which allow reading three transmitters’ registers to be read into one array, assuming contiguous transmitters.
SI FTA 1 SI Array 1 SI Array 2 SI Array 3 SI Array 16 XYR-01 XYR-04 XYR-07 XYR-45 Starting Reg: 20011 Starting Reg: 20041 Starting Reg: 20071 Starting Reg: 20161 1 Device Type 1 Device Type 1 Device Type 1 Device Type 2 Device Status 2 Device Status 2 Device Status 2 Device Status 3 PV1 3 PV1 3 PV1 3 PV1 4 PV2 4 PV2 4 PV2 4 PV2 5 PV3 5 PV3 5 PV3 5 PV3 XYR-02 XYR-05 XYR-08 XYR-46 6 Device Type 6 Device Type 6 Device Type 6 Device Type 7 Device Status 7 Device Status 7 Device Status 7 Device Status 8 PV1 8 PV1 8 PV1 8 PV1 9 PV2 9 PV2 9 PV2 9 PV2 10 PV3 10 PV3 10 PV3 10 PV3 XYR-03 XYR-06 XYR-09 XYR-47 11 Device Type 11 Device Type 11 Device Type 11 Device Type 12 Device Status 12 Device Status 12 Device Status 12 Device Status 13 PV1 13 PV1 13 PV1 13 PV1 14 PV2 14 PV2 14 PV2 14 PV2 15 PV3 15 PV3 15 PV3 15 PV3 Fig. 9 Examples of Transmitters Starting Registers Example: consider a system with 3 transmitters #7, 8 & 9 connected to FTA number 1. They are to be configured in an array, NNSTIX = 20071 and the NNUMERIC = 15. The Base Radio registers are 16-bit un-signed integers and can be used to monitor the status of the base radio and the communication status of all transmitters. The NNSTIX for the Base Radio is 90001 and the NNUMERIC is 10.
The figure below is an example of an array channel function block for a group of three (3) wireless transmitters. Add the appropriate amount of pins to the numeric array to match your configured NNUMERIC.
Fig 10. Fig 7 Example of SINNUMRRCH with three XYR5000 transmitters
Once completed, load the CM to the controller. The system is now ready for monitoring the array values. Engineering Units: The XYR5000 transmitters broadcast in Base Engineering units as listed below. An AUXCAL block will
be needed to convert from Base Engineering units to any other engineering units.
Device Type Value Acoustic Counts
Pressure PSI
Differential Pressure InH2O @68F
Temperature °C
Fig.11 XYR5000 Base Engineering Units
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Appendix A - REGMODE Modbus Mapping Settings
Table I Holding Registers (REGMODE Only)
Device ID = Base Radio Modbus ID
Register Address Description Register Type 20001 + (RF ID x 10) Device Type (See Table II) 20002 + (RF ID x 10) Device Type (See Table II)
(32 – Bit IEEE Floating Point)
20003 + (RF ID x 10) Device Status (See Table III) 20004 + (RF ID x 10) Device Status (See Table III)
(32 – Bit IEEE Floating Point)
20005 + (RF ID x 10) Primary Sensor Value 20006 + (RF ID x 10) Primary Sensor Value
(32 – Bit IEEE Floating Point)
20007 + (RF ID x 10) Secondary Sensor Value 20008 + (RF ID x 10) Secondary Sensor Value
(32 – Bit IEEE Floating Point)
20009 + (RF ID x 10) Tertiary Sensor Value 20010 + (RF ID x 10) Tertiary Sensor Value
(32 – Bit IEEE Floating Point)
Table II Value Device Type Va l u e Device Type Va l u e Device Type
0 Acoustic Monitor 7 Level Sensor 14 Split DP (300 inH2O) 1 RTD 8 Split RTD 15 DP (25 Psid) 2 Pressure 9 Split Pressure 16 Split DP (25 Psid) 3 Dual 0-10V Input 10 Split Dual Thermocouple 17 DP (100 Psid) 4 Dual 4-20mA Input 11 DP (100 inH2O) 18 Split DP (100 Psid) 5 Thermocouple 12 Split DP (100 inH2O) 19 DP (300 Psid) 6 Reserved 13 DP (300 inH2O) 20 Split DP (300 Psid)
Table III
Value Device Status Acoustic Temp T/C
Temp RTD Pressure Dual
0-10 V Dual 4-20 mA
1 (Bit 1) Transmitter Online
2 (Bit 2) Low Battery Condition < 2.9 V < 2.9 V < 2.9 V < 2.9 V < 2.9 V < 2.9 V
4 (Bit 3) Alarm Condition
8 (Bit 4) Sensor Error Condition < - 15 mV < 2 Ω < - 0.2% FS < - 0.3V < - 3mA
16(Bit 5) Sensor Overrange Condition 100 - 150% FS 13 V 26 – 100 mA
32(Bit 6) System Error Condition > 100 mV > 480Ω >150% FS > 13 V >100 mA
64 (Bit 7) Switch Input 1 High N/A N/A N/A N/A N/A N/A
127 (Bit 8) Switch Input 2 High N/A N/A N/A N/A N/A N/A
256 (Bits 9) Sq. Rt Function ON (DP) N/A N/A N/A N/A N/A N/A
Transmitter Status Registers: The statuses of the XYR5000 wireless transmitters must be “unpacked” from the individual 32-Bit IEEE Floating Point holding registers. To decode the transmitter statuses, take the value of the register and subtract the largest value listed in Table III that does not cause the result to be negative (-). Take the resulting total from the subtraction and subtract the next largest number possible and so on until the net result is zero (0). Each value used in the subtraction indicates the status or statuses of the XYR5000 Wireless transmitters. This can be done using the AUXCALC block in control builder.
EXperion PKS Integration.doc Honeywell Page 13 of 15
The Base Radio holding registers are 16-bit un-signed integers and can be used to monitor the status of the base radio and the communication status of all transmitters. The Base Radio Device Type is 255. Table IV Base Radio Holding Registers
Device ID: 1 to 247 Max
Register Address Description Register Type 90001 Device Type 16-Bit Unsigned 90002 Device Status (See Table VI) 16-Bit Unsigned 90003 No. Of Transmitters Expected 16-Bit Unsigned 90004 No. Of Transmitters Communicating 16-Bit Unsigned 90005 Online/Offline Status Field Units 1-16 16-Bit Unsigned 90006 Online/Offline Status Field Units 17-32 16-Bit Unsigned 90007 Online/Offline Status Field Units 33-48 16-Bit Unsigned 90008 Online/Offline Status Field Units 49-50 16-Bit Unsigned 90009 Reserved Future Use 16-Bit Unsigned 90010 Reserved Future Use 16-Bit Unsigned
The values for the Online/Offline Status values of XYR5000 transmitters 1 to 16 are shown in Table V. The remaining online /offline status holding registers hold the status of the remaining XYR5000 transmitters with RF ID’s 17 through 50. Table V
Value
Transmitter Device Status
Value
Transmitter Device Status
1 Transmitter 1 Online Status 257 Transmitter 9 Online Status 2 Transmitter 2 Online Status 512 Transmitter 10 Online Status 4 Transmitter 3 Online Status 1024 Transmitter 11 Online Status
8 Transmitter 4 Online Status 2048 Transmitter 12 Online Status 16 Transmitter 5 Online Status 4096 Transmitter 13 Online Status 32 Transmitter 6 Online Status 8192 Transmitter 14 Online Status
64 Transmitter 7 Online Status 16384 Transmitter 15 Online Status 127 Transmitter 8 Online Status 32768 Transmitter 16 Online Status
Base Radio On/Offline Transmitter Registers The online/offline status of the wireless transmitters 1 – 50 must be “unpacked” from the individual 16-Bit Unsigned Integer holding registers. To decode the online/offline status, take the value of the register and subtract the largest value listed in Table V that does not cause the result to be negative (-). Take the resulting total from the subtraction and subtract the next largest number possible and so on until the net result is zero (0). Each value used in the subtraction indicates which XYR5000 Wireless transmitter is Online. The following are the values for the Base Radio Device Status holding registers. These registers are bit field registers represented as a 16-bit unsigned Integer. Table VI Value Base Radio Status
1 Base Radio Online
2+ Reserved for Future Use
Appendix B - Base Radio Menu Map
EXperion PKS Integration.doc Honeywell Page 14 of 15
Appendix C – Wiring Diagram
EXperion PKS Integration.doc Honeywell Page 15 of 15
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No:
A
J3J1
J2
Mod
bus
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MU
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M12
1 2 3 4 5
J3J1
J2
1 2 3 4 5
Cha
nnel
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6
Pow
erA
dapt
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PC
01
Mod
bus
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MU
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M12
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W12
0 O
hm
Expe
rion
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SIMTC-MUX021
SIMTC-MUX021
SIMTC-MUX021
Max
48
Wire
less
Tran
smitt
ers
Per
Mod
bus
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12-3
0 V
dcP
ower
Sup
ply
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iring
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Tw
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ival
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Stra
nded
Cop
per
Beld
en
Tape
Bac
kS
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d
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232/
485
Con
verto
r
Max
48
Wire
less
Tran
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ers
Per
Mod
bus
FTA
GND24V
B / Tx -A / Tx +
RS
485
GND24V
B / Tx -A / Tx +
Hol
ding
Reg
iste
rs (R
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ase
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2000
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Prim
ary
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Sec
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2000
9 +(
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ngin
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)(3
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)
Valu
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ustic
Mon
itor W
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mitt
er1
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pera
ture
Wire
less
Tra
nsm
itter
2P
ress
ure
Wire
less
Tra
nsm
itter
3D
ual 0
-10V
Inpu
t Wire
less
Tra
nsm
itter
4D
ual 4
-20m
A In
put W
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ss T
rans
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Dua
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ple
Tran
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er11
Diff
eren
tial P
ress
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Tran
smitt
er (1
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Spl
it D
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l Pre
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e Tr
ansm
itter
(100
inH
2O)
13D
iffer
entia
l Pre
ssur
e Tr
ansm
itter
(300
inH
2O)
14S
plit
Diff
eren
tial P
ress
ure
Tran
smitt
er (3
00 in
H2O
)15
Diff
eren
tial P
ress
ure
Tran
smitt
er (2
5 P
sid)
16S
plit
Diff
eren
tial P
ress
ure
Tran
msi
tter (
25 P
sid)
17D
iffer
enta
il P
ress
ure
Tran
smitt
er (1
00 P
sid)
18S
plit
Diff
eren
tial P
ress
ure
Tran
smitt
er (1
00 P
sid)
19D
iffer
entia
l Pre
ssur
e Tr
ansm
itter
(300
Psi
d)20
Spl
it D
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enta
il P
ress
ure
Tran
smitt
er (3
00 P
sid)
Mod
bus
A-B+
Hon
eyw
ell