Johnson Controls OpenBlue Industrial Refrigeration Gateway Installation guide

Johnson Controls
Brand
Johnson Controls
Model
OpenBlue Industrial Refrigeration Gateway
Type
Installation guide
LIT-12013969
Digital Solutions
www.johnsoncontrols.com
2022-12-01
OpenBlue Industrial Refrigeration
Gateway Installation and Commissioning
Guide
2 OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide
Contents
ContentsIntroduction...................................................................................................................................................... 5
Supported equipment types................................................................................................................ 5
Gateway components........................................................................................................................... 5
Installation and commissioning requirements............................................................................................ 5
Installation and commissioning sequence................................................................................................... 6
Performing a site survey................................................................................................................................. 6
Installing the gateway..................................................................................................................................... 7
Unpacking and connecting the devices.............................................................................................. 7
Preparing for commissioning...............................................................................................................9
Commissioning the gateway.......................................................................................................................... 9
Accessing the OpenBlue Bridge user interface................................................................................. 9
Commissioning to OpenBlue Cloud.................................................................................................. 10
Configuring data points for Modbus devices...................................................................................10
Creating a Modbus profile........................................................................................................................ 10
Modbus profile template example...........................................................................................................12
Uploading a Modbus profile into OpenBlue Bridge.............................................................................. 13
Configuring a Modbus device in OpenBlue Bridge UI...........................................................................13
Configuring data points for OPC-UA devices................................................................................... 14
Configuring an OPC-UA device in OpenBlue Bridge UI.........................................................................14
Viewing the OPC-UA device in OpenBlue Bridge UI.............................................................................. 15
Verifying and controlling data points................................................................................................15
Troubleshooting............................................................................................................................................. 15
ICG-150 LED indicators show a fault................................................................................................. 15
Solution................................................................................................................................................. 16
Product warranty............................................................................................................................................16
Software terms............................................................................................................................................... 16
Contact information.......................................................................................................................................16
OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide 3
4 OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide
Introduction
The OpenBlue Industrial Refrigeration Gateway provides remote management and cloud
connection for your refrigeration equipment.
The OpenBlue Industrial Refrigeration solution leverages data analytics, consolidated reporting,
and Johnson Controls expert engineering services to help you identify reliability and maintenance
risks. The solution incorporates dashboards, reporting, and an alarm system. The reports and
dashboards are configured to suit the specific site system setup, and you can also define their own
dashboard to add suitable data points and sensors for trending and analytics.
Supported equipment types
The OpenBlue Industrial Refrigeration Gateway connects to the following equipment types:
• Programmable Logic Controllers (PLCs), for example, Johnson Controls® Frick® and Sabroe®
control systems, Allen-Bradley ControlLogix®, or Siemens SIMATIC controllers
• UniSAB III controllers
• Frick Quantum™ HD Panel
The gateway collects data from industrial refrigeration equipment, such as compressors,
condensers, evaporators, vessels, and pumps, and forwards the data to OpenBlue Cloud.
Gateway components
The OpenBlue Industrial Refrigeration Gateway consists of the following equipment:
• ICG-x86: a compact computer that runs OpenBlue Bridge and connects to your refrigeration
equipment through Modbus or OPC-UA.
• Tempered® Airwall™ 75: a security gateway that protects against cyberattacks. For more
information, refer to https://www.tempered.io/.
• ICG-150: an optional device that provides cellular connection to the Internet for the ICG-x86.
For detailed specifications, refer to the OpenBlue Industrial Refrigeration Gateway Datasheet
(LIT-1901189).
Installation and commissioning requirements
Ensure that you have the following items available:
• An ICG-x86 with the OpenBlue Bridge server installed and an Ethernet cable for the site
network connection
• A Tempered Airwall 75 series security gateway with an Ethernet cable for the connection to the
ICG-x86
• If you use cellular connection to the Internet, an ICG-150 with one or two active SIM cards and
an Ethernet cable for the connection to the Tempered Airwall 75 series security gateway
• If you use wired connection to the Internet, an Ethernet cable for the connection to the
Internet source
• A laptop with an Ethernet cable for the site network connection and with SSH software, for
example PuTTY or MobaXterm
• A monitor with a DisplayPort connector
5OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide
Installation and commissioning sequence
See the following image and list for an overview of the installation sequence for the OpenBlue
Industrial Refrigeration Gateway.
Figure 1: Overview of wired Internet connection (left), and cellular Internet connection
(right)
1. Perform a site survey. See Performing a site survey.
2. Install the ICG-x86 and the Airwall security gateway. If you use cellular connection to the
Internet, also install the ICG-150. See Installing the gateway.
3. Commission the ICG-x86. See Commissioning the gateway.
Performing a site survey
To perform a site survey, complete the following steps:
1. Obtain the site architecture drawing.
2. Inspect the piping and instrumentation diagram of the industrial refrigeration process.
3. Create a list of the devices that you want to connect to the OpenBlue Industrial Refrigeration
Gateway.
4. For each device you want to connect, create a list of the data points that you want to
integrate in the cloud.
OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide6
5. Check the location of the power supply for the gateway and plan for any additional power
cabling work that may be necessary.
Installing the gateway
Gateway installation includes unpacking, connecting, and powering on the gateway devices and
connecting your laptop to the site network to prepare for commissioning.
Unpacking and connecting the devices
1. Open the gateway kit box and inspect the contents for any damage. If you find any damage,
return the kit.
2. Unpack the devices and place them according to the site plan that the customer approved.
3. Complete the following substeps to create the Ethernet cable connections. For an overview,
see the following figures.
Figure 2: Cellular Internet cabling
7OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide
Figure 3: Wired Internet cabling
a. Use an Ethernet cable to connect the leftmost Ethernet port on the ICG-x86 to Ethernet
port 2 on the Airwall security gateway.
b. If you use cellular connection to the Internet, use an Ethernet cable to connect Ethernet
port 1 on the Airwall security gateway to the WAN/LAN1 port on the ICG-150.
Note: A custom port forwarding rule is in place to forward all traffic inbound
to the ICG-150 on port 8922 to the ICG-x86's port 22. This provides SSH access
into the ICG-x86. If any of the networks the gateway connects to use 192.168.2.x,
then change the configuration for the WAN/LAN1 port on the ICG-150 to prevent
routing problems.
c. If you use a wired Internet connection, use an Ethernet cable to connect Ethernet port 1
on the Airwall security gateway to an Internet source.
d. Connect the ICG-x86 to the site network. Use an Ethernet cable to connect the
rightmost Ethernet port on the ICG-x86 to the site switch or hub.
4. If you use an ICG-150, power it on, and check that the ICG-150 LED indicators show that the
device is connected:
Table 1: LED indicators for connection status
LED indicator LED indicator status when connected
Power Red
Status Green
Cellular Yellow
OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide8
Table 1: LED indicators for connection status
LED indicator LED indicator status when connected
Signal Green, yellow, or red
Note: Yellow or red light means a weak signal. If you experi-
ence communication issues, improve the signal strength. For
more information, see Troubleshooting.
WiFi • Fast blink: Wi-Fi access point mode
• Random blink: Wi-Fi client mode
• Off: Wi-Fi is off
If the LED indicators do not show a working connection, see Troubleshooting.
5. To configure the Airwall security gateway, complete the following steps:
a. Power on the Airwall security gateway and ensure that it can connect to the Internet.
b. Connect your laptop to the micro-USB console port on the Airwall gateway.
Note: If you need further guidance, contact Tempered technical support.
Preparing for commissioning
1. With your laptop powered off, use an Ethernet cable to connect your laptop to the site
network.
Note: Do not connect your laptop directly to any of the ICG devices.
2. Power on the ICG-x86.
Note: The ICG-x86 receives power through a barrel connector. If necessary, swap the AC
plug on the ICG-x86 power supply to the correct country plug.
3. Power on your laptop.
4. Optional: Connect a USB keyboard and USB mouse to the ICG-x86.
Commissioning the gateway
Commissioning the gateway includes configuring access for the OpenBlue bridge user interface,
configuring the data points, and commissioning the OpenBlue Bridge server to OpenBlue Cloud.
Accessing the OpenBlue Bridge user interface
About this task:
To configure OpenBlue Bridge, use the web-based UI. To access the UI, you must determine the IP
address of the OpenBlue Bridge and then navigate to the IP address in a browser.
1. To determine the IP address of OpenBlue Bridge, connect a monitor to one of the DisplayPort
connectors on the ICG-x86-L.
When the monitor is connected, it displays the IP address.
2. Make sure that your laptop is on the same subnet as OpenBlue Bridge, then open a browser,
and type the OpenBlue Bridge IP address into the URL field.
3. Sign in with the following credentials:
-EmailAddress: [email protected]
-Password: OpenB1ueBr!dge
9OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide
Note: OpenBlue Bridge supports a single sign-in configuration (single user).
4. Change the password, and sign in with the new password.
After sign-in, the OpenBlue Bridge UI home page appears. The home page contains a list of
configuration and integration options in a menu on the left.
Note: Not every OpenBlue Bridge installation uses all of the available services, which
means that some of the menus can be blank for a specific installation.
Commissioning to OpenBlue Cloud
To connect OpenBlue Bridge to OpenBlue Cloud, complete the following steps:
1. Sign in to the OpenBlue Bridge configuration UI.
2. In the navigation pane, click OpenBlue Cloud.
The OpenBlue Cloud page appears that shows the list of cloud connectors. If no connectors
exist, the page displays an +Add Connector button.
3. If no connectors exist, click + Add Connector.
4. In the upper-right corner, click + Add Connector.
5. In the Add New Connector window, fill the following fields:
-ConnectorName: enter a name for the connector.
Note: The name must be lowercase and start with the string connector, for
example, connectortest.
-ConnectorType: select the ConnectionString type.
-ConnectionString: enter the connection string that you receive from the team
responsible for the connection on the OpenBlue Cloud side.
- Optionally, select the Enable Message Compression check box to improve the
throughput of the connection.
6. Click Add.
The connector addition process can take approximately 30 seconds. To verify the new connec-
tor, log out of the OpenBlue Bridge UI, and on the OpenBlue Cloud UI, check that you can see
a corresponding logout message.
Configuring data points for Modbus devices
You must specify the industrial refrigeration data points that the gateway manages.
Creating a Modbus profile
1. In the left-pane, click Asset Management, and in the upper-left corner, click Add Asset.
2. From the Asset Type list, select Profile.
3. From the Manufacturer list, select JCI.
4. From the Model list, select Modbus Profile.
5. To download the OPC Profile template, click Modbus Profile template can be downloaded
here.
6. Open the template you downloaded and type the values that are in the following table:
OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide10
Table 2: Modbus template fields
Attribute Required or optional Description
Name Required Unique name for the data point.
Description Optional Description of the data point.
ValueType Required The data type of the value represented by the
point.
Value Read/
Write
Required Signifies whether the data point on the Modbus
device has read-write capability.
Use Read for the following Primary Table values:
• DISCRETES_INPUT
• INPUT_REGISTERS
Use ReadWrite for the following Primary Table
values:
• COILS
• HOLDING_REGISTERS
Value Scale Optional Factor to multiply a reading by before it is returned.
Used with rawType and ValueType together to
convert integer data from a point to float data for
output.
Units Optional Units of value represented by the data point.
Primary Table Required The primary table must be one of the following
values:
• HOLDING_REGISTERS
• DISCRETES_INPUT
• COILS
• INPUT_REGISTERS
Starting
Address
Required The address for the Modbus device
rawType Optional Defines the binary data read from the Modbus
device and uses a value descriptor data type
to identify the data type that the user wants to
receive.
11OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide
Table 2: Modbus template fields
Attribute Required or optional Description
isByteSwap Optional Defines whether to swap the byte on reading little-
endian data to transform to big-endian format.
OBB Modbus Device Service uses big-endian
format. If the Modbus device uses little-endian
format, set this attribute to true to correctly
convert the data.
isWordSwap Optional Defines whether to use 16-bit segments, also
known as words, to re-order the byte sequence
with big-endian or little-endian formats. To re-
order the byte sequence, set this attribute to true.
7. Save the changes to your template.
Modbus profile template example
The following Modbus profile template example contains data points for a Quantum HD Controller.
Table 3: Modbus profile template example
Modbus Profile Template
Name QHD_IREF_MODBUS
Manufacturer JCI_FRICK
Model QHD_MODBUS
Description Configuration of data values using MODBUS for Quantum HD
Controller
Device Resources / Data Points (Gray columns are optional)
Name Description ValueType Value
Read/
Write
Value Scale Units Primary Table Starting
Address
rawType isByteSwap isWordSwap
AlarmMessage1 Alarm Message 1 Float32 Read 0.1 HOLDING_REGIS
TERS
3071 INT16 FALSE FALSE
AlarmMessage2 Alarm Message 2 Float32 Read 0.1 HOLDING_REGIS
TERS
3072 INT16 FALSE FALSE
AlarmMessage3 Alarm Message 3 Float32 Read 0.1 HOLDING_REGIS
TERS
3073 INT16 FALSE FALSE
AlarmMessage4 Alarm Message 4 Float32 Read 0.1 HOLDING_REGIS
TERS
3074 INT16 FALSE FALSE
AlarmMessage5 Alarm Message 5 Float32 Read 0.1 HOLDING_REGIS
TERS
3075 INT16 FALSE FALSE
AlarmMessage6 Alarm Message 6 Float32 Read 0.1 HOLDING_REGIS
TERS
3076 INT16 FALSE FALSE
AlarmMessage7 Alarm Message 7 Float32 Read 0.1 HOLDING_REGIS
TERS
3077 INT16 FALSE FALSE
AlarmMessage8 Alarm Message 8 Float32 Read 0.1 HOLDING_REGIS
TERS
3078 INT16 FALSE FALSE
AlarmMessage9 Alarm Message 9 Float32 Read 0.1 HOLDING_REGIS
TERS
3079 INT16 FALSE FALSE
AlarmMessage10 Alarm Message 10 Float32 Read 0.1 HOLDING_REGIS
TERS
3080 INT16 FALSE FALSE
CalculatedCapacity Calculated Capacity Float32 Read 0.1 % HOLDING_REGIS
TERS
3001 INT16 FALSE FALSE
CapacitySlidePosition Capacity Slide Position Float32 Read 0.1 % HOLDING_REGIS
TERS
2001 INT16 FALSE FALSE
CompressorRunning Compressor Running Float32 Read 0.1 HOLDING_REGIS
TERS
1028 INT16 FALSE FALSE
OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide12
Table 3: Modbus profile template example
CompressorSpeedOutput Compressor Speed
Output
Float32 Read 0.1 % HOLDING_REGIS
TERS
2070 INT16 FALSE FALSE
CurrentRegulationSetpoint Current Regulation
Setpoint
Float32 Read 0.00689476 BAR HOLDING_REGIS
TERS
3062 INT16 FALSE FALSE
CurrentRegulationValue Current Regulation
Value
Float32 Read 0.00689476 BAR HOLDING_REGIS
TERS
3061 INT16 FALSE FALSE
DischargeGasSuperheat Discharge GasSuper
heat
Float32 Read 0.1 C HOLDING_REGIS
TERS
3021 INT16 FALSE FALSE
DischargePressure Discharge Pressure Float32 Read 0.00689476 BAR HOLDING_REGIS
TERS
2004 INT16 FALSE FALSE
DischargeTemperature Discharge Temperature Float32 Read 0.1 C HOLDING_REGIS
TERS
2013 INT16 FALSE FALSE
EZCoolLIOC EZ Cool LIOC Float32 Read 0.1 % HOLDING_REGIS
TERS
2099 INT16 FALSE FALSE
FilterDifferentialPressure Filter Differential
Pressure
Float32 Read 0.00689476 BAR HOLDING_REGIS
TERS
3007 INT16 FALSE FALSE
FilterPressure Filter Pressure Float32 Read 0.00689476 BAR HOLDING_REGIS
TERS
2008 INT16 FALSE FALSE
MotorAmps Motor Amps Float32 Read 0.1 Amps HOLDING_REGIS
TERS
2028 INT16 FALSE FALSE
OilLevelSwitch Oil Level Switch Float32 Read 0.1 HOLDING_REGIS
TERS
1002 INT16 FALSE FALSE
OilPressure Oil Pressure Float32 Read 0.00689476 BAR HOLDING_REGIS
TERS
2005 INT16 FALSE FALSE
OilTemperature Oil Temperature Float32 Read 0.1 C HOLDING_REGIS
TERS
2014 INT16 FALSE FALSE
RunHoursThousands Run Hours Thousands Float32 Read 0.1 HOLDING_REGIS
TERS
3081 INT16 FALSE FALSE
RunHoursUnits Run Hours Units Float32 Read 0.1 HOLDING_REGIS
TERS
3082 INT16 FALSE FALSE
SeparatorOilTemperature Separator Oil
Temperature
Float32 Read 0.1 C HOLDING_REGIS
TERS
2015 INT16 FALSE FALSE
SuctionGasSuperheat Suction Gas Superheat Float32 Read 0.1 C HOLDING_REGIS
TERS
3020 INT16 FALSE FALSE
SuctionPressure Suction Pressure Float32 Read 0.00689476 BAR HOLDING_REGIS
TERS
2003 INT16 FALSE FALSE
SuctionTemperature Suction Temperature Float32 Read 0.1 C HOLDING_REGIS
TERS
2012 INT16 FALSE FALSE
SystemCompressionRatio System Compression
Ratio
Float32 Read 0.1 % HOLDING_REGIS
TERS
3009 INT16 FALSE FALSE
VolumeSlidePosition Volume Slide Position Float32 Read 0.1 HOLDING_REGIS
TERS
2002 INT16 FALSE FALSE
Uploading a Modbus profile into OpenBlue Bridge
1. In the left-pane, click Asset Management, and in the upper-left corner, click Add Asset.
2. From the Asset Type list, select Profile.
3. From the Manufacturer list, select JCI.
4. From the Model list, select Modbus Profile.
5. Click Upload.
6. Select the Modbus template that you have saved your changes to. See Creating a Modbus
profile.
Configuring a Modbus device in OpenBlue Bridge UI
1. In the left-pane, click Asset Management, and in the upper-left corner, click Add Asset.
2. From the Asset Type list, select Modbus.
3. From the Manufacturer and Model lists, select the relevant values for the profile of the
Modbus device.
4. Type the Modbus server connection parameters displayed in the following table, and click
Submit:
13OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide
Table 4: Connection parameters to Modbus server
Field Description
Profile Name The name of the Modbus profile.
Device Name The name of the Modbus device.
IP Address The IP address of Modbus server.
Port The port number of the Modbus server.
Device Unit ID The device unit ID of the Modbus device.
Configuring data points for OPC-UA devices
You must specify the industrial refrigeration data points that the gateway manages.
Configuring an OPC-UA device in OpenBlue Bridge UI
1. In the left-pane, click Asset Management, and in the upper-left corner, click Add Asset.
2. From the Asset Type list, select OPC.
3. From the Manufacturer list, select JCI, and from the Model list, select OPC Device.
4. Type the OPC-UA server connection parameters displayed in Table 5, and click Submit.
Note:
If the OPC server is protected with credentials, the following fields are mandatory:
- Security
- ApplicationUri
- Certificate
- PrivateKey
- Username
- Password
Table 5: Connection parameters to OPC-UA server
Property or object name Comments
Device Name The unique name of the device.
Address The address for the OPC device. Include the port and path, if
necessary. For example:
10.211.55.40:53530/OPCUA/SimulationServer
Note: Do not include the protocol in the address. If the
address is incorrect, OpenBlue Bridge cannot connect to the
device.
Security The security policy used when you connect to the OPC-UA
server. The following values are valid: Basic128Rsa15 or
Basic256Sha256.
ApplicationUri The URI associated with any certificate used to connect to the
OPC-UA device.
OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide14
Table 5: Connection parameters to OPC-UA server
Property or object name Comments
Certificate The name of the DER file that contains the certificate to use for
a secure connection. Make sure to include the file name and the
extension. The certificate must be trusted by the OPC-UA server.
For more information, refer to the device documentation.
Generate and upload your own certificate to OpenBlue Bridge.
Place the certificate and private key files in the /keys folder. If
the /keys folder does not exist, create the folder.
PrivateKey The name of the DER file that contains the private key to use
when establishing a secure connection. Make sure to include the
file name and the extension.
Username The user name used when you connect to an endpoint.
Password The Base64-encoded password associated with the user name
used when you connect to an endpoint.
Viewing the OPC-UA device in OpenBlue Bridge UI
• In the left-pane, click Asset Management and the added OPC-UA device is displayed.
Verifying and controlling data points
About this task:
After you set up data points, verify that the points are enabled and, if necessary, change the data
poll interval and the threshold that determines whether to send new data values to OpenBlue
Cloud.
1. To view the properties of a data point, in the asset list, click the three-dot menu of the
relevant row, and select Properties. Verify that the Enabled parameter is true, which
indicates communication with the data source.
2. To control a data point, in the asset list, click the three-dot menu of the relevant row, and
select Control Asset. If necessary, change the following options:
- PollInterval: you can set the interval between data polls for the point.
- Threshold: when the value of the data point changes, OpenBlue Bridge sends the new
value to OpenBlue Cloud if the difference between the old value and the new value is
greater than this threshold.
Troubleshooting
ICG-150 LED indicators show a fault
The following table contains the ICG-150 fault conditions that the LED indicators show.
15OpenBlue Industrial Refrigeration Gateway Installation and Commissioning Guide
Table 6: ICG-150 LED indicators
Status indicationLED indicator
No power Fault SIM failure Connecting Connected
Power Red Red Red Red
Status Green Green Green
Cellular Yellow,
blinking
Yellow
Signal Off • Red: low signal strength
• Yellow: medium signal strength
• Green: high signal strength
WiFi
Off
Off
Off
Off • Fast blink: Wi-Fi access point mode
• Random blink: Wi-Fi client mode
• Off: Wi-Fi is off
Solution
• Weak signal strength: move the ICG-150 closer to a window or away from metal walls, piping,
or other objects that might weaken the signal.
• No power:
a. Check the power supply for tripped fuses and investigate the cause.
b. Check the power cables and replace them if necessary.
c. Return the ICG unit for replacement.
• Fault:
a. Power off the unit and then power on the unit.
b. Reset the unit with the Reset button.
• SIM failure:
a. Power off the unit and then power on the unit.
b. Replace the SIM card. If you use two SIM cards, identify the potentially faulty one and
replace it.
c. Reset the unit with the Reset button.
Product warranty
This product is covered by a limited warranty, details of which can be found at
www.johnsoncontrols.com/buildingswarranty.
Software terms
Use of the software that is in (or constitutes) this product, or access to the cloud, or hosted
services applicable to this product, if any, is subject to applicable end-user license, open-
source software information, and other terms set forth at http://www.johnsoncontrols.com/
techterms. Your use of this product constitutes an agreement to such terms.
Contact information
Contact your local Johnson Controls representative: www.johnsoncontrols.com/locations
Contact Johnson Controls: www.johnsoncontrols.com/contact-us
© 2022 Johnson Controls. All rights reserved. All specifications and other information shown were current as of document
revision and are subject to change without notice.
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Johnson Controls OpenBlue Industrial Refrigeration Gateway Installation guide

Johnson Controls
Brand
Johnson Controls
Model
OpenBlue Industrial Refrigeration Gateway
Type
Installation guide
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