Johnson Controls OpenBlue Industrial Refrigeration Gateway Installation guide

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 • 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

revision and are subject to change without notice.

Johnson Controls OpenBlue Industrial Refrigeration Gateway Installation guide

Johnson Controls OpenBlue Industrial Refrigeration Gateway Installation guide

Johnson Controls OpenBlue Industrial Refrigeration Gateway Installation guide

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