Data Collector 2.03.00

User Guide
Data Collector - V 2.03.00

Data flow monitoring application for LPG cylinder filling systems
Revision no: 01
IFS reference no: XXXXXXX
DRAFT EDITION
Share knowledge, make others good

Preface
The English (United Kingdom) language version of this publication is the master user guide for the
equipment/ system mentioned in the cover page.
The scope of this user guide is to provide the necessary information and references for the
operation of the equipment/ system.
All personnel involved with the operation of the equipment/ system must read, understand and
follow the instructions in this guide: to maintain a hazard free environment, and; to optimise the
equipment performance.
Adhere to the information given under the SAFETY NOTE in the following page.
The Kosan Crisplant Group appreciates proposals and feedback for the service improvement.
Copyright note
Copyright © Kosan Crisplant Group
No part of this document may be reproduced, transmitted, stored or used in any other manner
prejudicial to the interests of the Copyright Holder.
Reproduction of the information in this document is allowed solely for the purpose of maintenance
and servicing of the equipment/ systems designed and installed by the Kosan Crisplant Group.
The Kosan Crisplant Group

P.O. Pedersens Vej 22, DK-8200 Aarhus N, Denmark
Phone +45 8740 3000 | Direct +45 8740 3062
Fax +45 8740 3010
service@kosancrisplant.com | www.kosancrisplant.com
DRAFT EDITION
Safety Note
Compliance to regulations, standards, and instructions

This equipment/ system is designed to operate in environments classified as explosive,
under the Directive 94/9/EC of the European Parliament and the Council and the related
international standards.
Complementary Directive 99/92/EC of the European Parliament and the Council and
the related international standards specify the workplace safety and health protection
requirements that should be followed by the equipment operators.
Failure to follow above requirements may cause loss of life, injury and damage to the
property.
Therefore, follow the international and national regulations applicable for the industry during
all activities related to the equipment/ system.
The safety instructions provided in this document are specific to the equipment, and in no
way replace the mandatory requirements set by the international and national regulations
and standards.
Hence, understand and follow the safety instructions provided in this document, within the
safety criteria set by the applicable international and national regulations and standards.
Standard symbols and annotations

Following symbols are used in this document to highlight special instructions or reference
information related to the equipment/ system.
Symbol Status Description
WARNING Mandatory/ critical safety instruction to prevent

injury to life and damage to the product / system
NOTE A reference to an important information/ feature
A special safety instruction denoted under any heading is equally applicable for all the sub
headings of that section/ sub section.
DRAFT EDITION
Document reference
This publication is uniquely defined by the following printed on all the subsequent pages: the
document title on header sections; the revision number on footer sections.
Document title: Data Collector - V 2.03.00
Revision number: 01
Document status: Master/ Translation IFS No: XXXXXXX R0X
Revision track record

The document revision history is summarized in the following table.
Revision Date Description

number
01 12.03.2001 Initial release
02 dd.mm.yyyy Update of user guide with a new format
Document Author : MIC/ VPA

Creation Date : 13.06.2014
Revision Editor : VPA
DRAFT EDITION
List of Contents
List of Contents
List of Contents.........................................................................................................1
1. Getting started .................................................................................................2
1.1 System features.................................................................................................... 2
1.2 How to use the application.................................................................................... 2
2. Data Collection Monitor ...................................................................................4
3. Network Monitor ..............................................................................................6
4. Machine Monitor ..............................................................................................9
5. How to set-up  ................................................................................................ 12

6. How to troubleshoot ...................................................................................... 15
Author : MIC/ VPA Revision Date : 16.07.2014 No : 01
DRAFT EDITION 1
Getting started
1. Getting started
Kosan Crisplant Data Collector is
- a user-friendly software application operated on a PC.
- u
sed for monitoring the signal flow of a data network used in an LPG cylinder filling
plant.
This document provides detailed information on how to operate the Kosan Crisplant
Data Collector version 2.03.00.
1.1 System features

The Data Collector allows the operator(s) to
- select the required data network/ channels.
- view the data flow status, in a given data network/ channel.
- save the report(s).
- print the report(s).
1.2 How to use the application

- Read and learn about the system, before use
The operators should have proper knowledge about the system to ensure safe and
efficient operation.
- Ask for assistance, in case of a doubt
Consult your local supervisors or the Kosan Crisplant representatives for clarifications.
To use the application
1 Start the PC and open the Data Collector Monitor [B].
2 Navigate to the required status information window(s).
The basic navigation is described in this section with reference to Figure 1.1.
DRAFT EDITION 2
Getting started
The application icon is Data

Collector icon [A]. A
Double clicking the Data
Collector icon A with the left
mouse button opens the Data
Collection Monitor [B].
B
The Data Collection Monitor [B]
displays
- the layout of the plant and its

system(s).
- the data transfer network(s).
-
a quick view of the data
transfer network status.
The interactive graphical user

interface allows the operator to C
navigate to the relevant network
and the sub level information
windows.
See
- section 2 for information on

Data Collection Monitor.

Network Monitor.

Machine Monitor.
Legend
A Data Collector icon
B Data Collection Monitor
C Network Monitor
D Machine Monitor
Figure 1.1 Basic monitoring steps
DRAFT EDITION 3
Data Collection Monitor
2. Data Collection Monitor

The Data Collection Monitor [B]
- is a dynamic user interface.
- provides the data network layout.
- allows the operator to access the relevant information.
See
B
-
Figure 2.1 for an
overview of Data b1
Collection Monitor.
b2
-
Table 2.1 for the
description on Data
b3
Collection Monitor
options. b4
b5
b4
b42 b43
b41 b44
Legend
B Data Collection Monitor
b1 Functionality bar
b2 Plant group bar
b3 System group bar
b4 Network monitor bar
b41 Collection bar
b42 Friendly name
b43 Message count
b44 Monitoring status
b5 Queue status bar
Figure 2.1 Data Collection Monitor
DRAFT EDITION 4
Data Collection Monitor
Functionality bar (b1)
The bar with the basic functions to handle the Data Collection Monitor.
Press icon to view the v ersion and build time
Press the icon to open up the Setting option.
Press the icon to minimize the application.
Press the icon to close the application.
Plant group bar (b2)
A bar with the information fields grouped according to the different filling plants.
System group bar (b3)
A bar with the information fields grouped according to the different systems.
Network monitor bar (b4)
A bar with the information fields grouped according to the different data networks or channels.
The bar provides the link to the relevant data windows.
Collection Collection bar moves right (by one click per each action) to indicate the tasks performed by
bar [b41] a given Network Monitor
Friendly Name used for the given network

name [b42]
Message Number of messges received by the given Network Monitor.

count [b43]
Monitoring Operating status of a given data network channel as described below:

status [b44] - Module Error: Critical error in the USB Module (PD3950/ KIGO) used for commuication
with the filling system
- Machine Error: An error in a machine covered by the data network/ channel. Error
details are avaialbe with the Network Monitor.
- Monitoring: S
ystem is under monitoring with no errors.
- Initiating: N
etwork Monitor is starting up and connecting with the HMI/ CUC
modules of the network.
- Waiting: N
etwork Monitor is booting up before the system initiation.
Network monitor bar (b4)
The bar with the data queue status.

Write Queue Amount of data awaiting to be written to the data base
TCP Queue Amount of data awaiting to be sent via TCP
Table 2.1 Data Collection Monitor
DRAFT EDITION 5
Network Monitor
3. Network Monitor
A Network Monitor [C] provides detailed information about a selected network.
See
C
-
Figure 3.1 for an c1
overview of Network
Monitor.
c2
-
Table 3.1 for the
description on
Network Monitor c3 c4
options.
c5
Legend
C Network Monitor
c1 Functionality bar
c2 Network monitor information area
c3 Average call duration graph
c4 Collection loop duration graph
c5 Machine overview
c2 c3
c21
c22
c31 c32 c33
c23
c4 c5
c58
c57
c41 c42 c43
c51 c52 c53 c54 c55 c56
Figure 3.1 Network Monitor
DRAFT EDITION 6
Network Monitor
Functionality bar (c1)
The bar with the basic functions to handle the Network Monitor
Network name
Press the icon to close the monitor. However, the monitor continues to operate at the
background.
Network monitoring information area (c2)

The notification area with the Network Monitor operating status. The operating status is notified
with any one of the following messages:
Data collection is Appears during the initiation of the monitor; the monitor remains inactive
initiating [c21]Data
Data collection is Appears and remains during the active stage of the Network Monitor when there
active [c22] are no errors. At this stage the operator can start the monitor for detailed data
analysis. Until the monitor is started, no data is fed to the graphical user interface
(GUI).
Data collection is in Appears when errors are detected in the monitor and/ or associated LPG filling
error [c23] machinery; and remains until the errors are corrected.
Average call duration graph (c3)
The bar graph that plots the average time between information request(s) (from the monitoring
system) and the response signals (from associated HMI/ CUC modules): The graph is active
only when the Network Monitor is in the active state.
Current response The last calculated average response time: The current response time for a given
time [c31] HMI/ CUC is calculated by averaging the last three response time results recorded
for the module).
Minimum response The minimum response time recorded from any individual machine in the system.
time [c32]
Maximum response The maximum response time recorded from any individual machine in the system.
time [c33]
Collection loop duration graph (c4)
A bar graph that plots the time taken (by the monitoring system) to scan information from all
associated HMI/ CUC modules of the network. The graph is active only when the Network
Monitor is in the active state.
Current scanning The last scan cycle time. The current scanning time is calculated by averaging the
time [c41] last five scan cycle time results recorded for the system.
Minimum scanning The minimum scan cycle time recorded for the system.
time [c42]
Maximum scanning The maximum scan cycle time recorded for the system.
time [c43]
Table 3.1 Network Monitor (continued to next page)
DRAFT EDITION 7
Network Monitor
Machine overview (c5)

The information overview window with the data communication status information from individual
machines (or the associated HMI/ CUC modules) of the network. Each active machine is
assigned with a bar (row).
Click on any machine bar to view the Machine Monitor with detailed information about the
relevant machine.
See section 4 for details on Machine Monitor.
Priority [c51] Priority status assigned to the machines are divided into three categories:
- High priority [H]: Assigned to the machines which are critical for the operation;
these machines are scanned during each data collecting cycle
(scan interval is less than 600ms)
- Low priority [L]:
Assigned to the machines which are less critical for the
operation. Only one low priority machine will be scanned
during each scan cycle.
- Status [S]: Assigned to the machines which does not deliver data to the
monitoring system. the online status of these machines are
checked every minute by the monitoring system.
Machine name The specific machine type: if more than a single machine is available from a given
[c52] machine type, the machine names are sequentially numbered starting from one
(1).
Successful The percentage of succesful responses to the total number of data requests sent
telegram count to the specific machine. A successful response is counted when the monitoring
[c53] system receives a complete reply from the relevant machine for a data request.
Data error count The percentage of data errors to the total number of data requests sent to the
[c54] specific machine. A data error is counted when the monitoring system detects a
communication failure that interrupts the data collection process.
Lost data count The percentage of no responses to the total number of data requests sent to the
[c55] specific machine. A no response is counted when the monitoring system does not
receive a complete reply from the relevant machine for a data request.
Machine call Similar to the Average call duration graph [c3]. Displayed data is only for the
duration graph specific machine.
[c56]
Offline status The machine is assumed as offline. The assumption is made when 10 or more Lost
notification data counts [c55] are detected by the system within ten seconds.
[c57]
(Grey background)
Error status The machine is assumed as faulty. The assumption is made when 10 or more Data
notification error counts [c54] are detected by the system within ten seconds. The diagnosed
[c58] error condition is displayed on the bar.
(Red background)
Table 3.1 Network Monitor (continued from previous page)
DRAFT EDITION 8
Machine Monitor
4. Machine Monitor
A Machine Monitor [D] provides detailed information about a selected machine.
See
D
-
Figure 4.1 for an
overview of Machine d1
Monitor.
-
Table 4.1 for the
description on Machine
Monitor options.
d21 d2
d22
d3
d31 d32 d33
d41
d4
d42
d43
d5
d51
d6
Legend
D Machine Monitor
d1 Functionality bar d4 Machine response summary
d2 Machine information area d5 Telegram call counter
d3 Average call duration graph d6 Messages
Figure 4.1 Machine Monitor
DRAFT EDITION 9
Machine Monitor
Functionality bar (d1)
The bar with the basic functions to handle the Machine Monitor.
Machine name
Press the icon to close the monitor.
Machine information area (d2)

The notification area with the machine operating status, and; the HMI/ CUC version with the
Functional (operating) mode.
Machine operating Operating status of a given machine as described below:
status [d21]Data - Machine has reported an error: C ritical error in the machine
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
CUC Version/ CUC/ HMI version/ Operating mode

Functionality ID
[d22]
Average call duration graph (d3)
The bar graph that plots the average time between information request(s) (received from the
monitoring system) and the response signals from the machine. The graph is active only when
the Network Monitor is in the active state.
Current response The last calculated average response time: The current response time for a given
time [d31] HMI/ CUC module is calculated by averaging the last three response time results
recorded for the module).
Minimum response The overall minimum response time

time [d32]
Maximum response The overall maximum response time
time [d33]
Machine response summary (d4)
The summary of the machine response to the data monitoring system.

Machine The percentage of sucessful telegrams to failed telegrams.
performance [d41]
Data collected The amount of successful data collections
[d42]
Active duration Total period of active operation without errors
[d43]
Table 4.1 Machine Monitor (continued to next page)
DRAFT EDITION 10
Machine Monitor
Telegram call counter (d5)
The summary of the telegram status displayed with a colour code.
Successful No of completely handled telegrams with no errors

Warnings No of telegrams handled with error messages
Errors No of telegram failures
Offline No of offline occurances
Message list (d6)
List of currently active messages generated for the specific machine
Table 4.1 Machine Monitor (continued from previous page)
DRAFT EDITION 11
How to set-up
5. How to set-up
The system provides the option to set-up the key features of the Data Collection
Monitor.
To set-up the data collection B

configuration
1
Click the Data collection
setting icon b12. b12
E
With step 1, the Data Collection e1
Settings menu [E] is opened.
When the system is started for e2

the first time, the settings are at
the default values.
e21
Identify and determine the
system parameters, before e22
any set-up
e3
The operator must identify
and know the required system e31
parameters, before performing
any set-up activity. Incorrect set- e32
up will cause inaccurate data e33
inputs.
e34
2
Set-up the required
parameters.
e4
See Table 5.1 for the description
of set-up parameters. e41
Legend e42
B Data Collection e7 Screen tip window e43
Monitor
b12 Data collection e8 Save button e44
setting icon
E Data Collection e45
Setting menu
e6
e1 Functionality bar e5 e6
e2 Collection lock
parameter set-up
e3 Startup parameter
set-up e7 e51
e4 TCP communication
set-up e52
e5 Message set-up
e6 Screen tip icon e8
Figure 5.1 Data Collection Settings
DRAFT EDITION 12
How to set-up
In addition, a short description on each parameter can be viewed by moving the cursor
onto the Screen tip icon [e6] (placed right of the relevant parameter cage).
3 Save the new settings with the Save button e8.
4 Restart the system to activate the new settings.
Functionality bar (e1)
The bar with the basic functions to handle the Data Collection Settings menu.
Press the icon to exit the menu.
Collection lock parameters set-up (e2)
The options to select a specific plant/ system or all plants and systems for data collection.
Plant search Set

Identifier [e21]Data - ‘0’ to collect data from all the plants.
- specifc plant number to collect data only from the set plant.
System search Set

Identifier [e21] - ‘0’ to collect data from all the systems.
- specifc system number to collect data only from the set system.
Startup Parameters set-up (e3)
The options to set-up how to start the Network Monitors.
Enable automatic Select the option (the cage is filled with blue colour) to start-up the Data Collection
start [e31] Monitor application during the PC start-up.
Deselect the option (the cage is filled with background colour) to disable the
automatic start-up. In this case, the operator needs to click on the application icon
to start-up the Data Collection Monitor.
Automatic start Set the time gap (in milliseconds) between the Data Collection Monitor start-up and
Delay [e32] initailization of the Network Monitors.
Enable backward Select the option (the cage is filled with blue colour) to enable the Data Collector to
compatibility [e33] store data for older Kosan Crisplant software versions.
This option should be enabled for
- CUC Monitor version 8.
- Report Control Centre (RCC) software released before version 3.03.00.
- SCADA system software released before version 2.00.00.
PNet Interface Type Set to

[e34] - V
igo oledb Interface, if PD3950/ 3930 black modules are used as process-data
interfaces.
- K
igo oledb Interface (Win Xp), if CP210x green modules are used as process-
data interfaces.
Table 5.1 Data Collection Settings (continued to next page)
DRAFT EDITION 13
How to set-up
TCP Communication (e4)
The options to set-up data transfer via TCP communication. In the TCP mode of data transfer,
each Network Monitor queues the collected data to a designated TCP data queue, and; TCP
transfers the data to the relevant receipient address(es) via the network.
Enable TCP Select the option (the cage is filled with blue colour) to transfer the data in TCP data
communication transfer mode.
[e41]
TCP Port [e42] Set the data transfer port. The port should match with the data receipient point.
TCP IP Address Set the data transfer IP address. The IP address should match with the data
[e43] receipient point.
TCP Server Type Set to

[e44] - A
ll data, to transfer all collected data via TCP.
- O
nly send Sortouts, to transfer only the data relevant to sorting out occurances
via the TCP.
Use Database time Select the option (the cage is filled with blue colour) to tag/ synchronise the
stamps [e45] telegrams with system database time settings.
If the option is disabled, the telegrams are tagged with localized time settings.
Message Logging (e5)

The options to set-up data transfer via TCP communication. In the enabled mode, messages are
logged to the installation directory/ path of the Data Collection Monitor. (Ex: if the Data Collection
Monitor is installed at C:\Program Files\Kosan Crisplant\Kosan Crisplant Data Collector, the log
files are written to the same directory)
Enable Message Select the option (the cage is filled with blue colour) to log the messages.
logging [e51]
Message Log Level Set to

Type [e52] - A
ll data, to log all activities.
- E
rrors only, to log only the errors.
Table 5.1 Data Collection Settings (continued from previous page)
DRAFT EDITION 14
How to troubleshoot
6. How to troubleshoot
Data Collector Monitor displays error messages in case of a fault. This section provides
the general troubleshooting steps according to the displayed error notifications.
- Follow the standard safety instructions/ procedures
- Beware of moving components and cylinders
- Stop the processes if required for troubleshooting
- Refer to relevant technical documents applicable for the system(s)
Fault Possible cause Rectification
For VIGO type application REFER to Installation of

n1 (with PD 3930/ PD3950 VIGO manual.
hardware modules) only.
n2 RECONFIGURE the USB.
Incorrect USB configuration.
RECONNECT to the system.
CHECK the system operation.
If the problem continues,
Module error: REPLACE the module.

Indicated by (1) Module
error notification n1, and For KIGO type application UNPLUG the USB Module.
(2) popup window n2 (with CP210x USB modules)
that appears with error only. REPLUG the USB Module.
details.
Improper USB connection. CHECK the system operation.
If the problem continues,
REPLACE the module.
Outdated software versions CONSULT the Kosan Crisplant

n3 installed on HMI/ CUC representative in case of a doubt.
module(s).
Machine error: UPDATE the HMI/ CUC operating
Indicated by Machine software.
error notification n3.
DRAFT EDITION 15
Kosan Crisplant a/s
P.O. Pedersens Vej 22
DK-8200 Aarhus N
Denmark
Tel : +45
8740 3000
Fax: +45 8740 3010
sales@kosancrisplant.com
service@kosancrisplant.com
www.kosancrisplant.com
www.flexspeed.info

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User Guide

Data Collector - V 2.03.00

IFS reference no: XXXXXXX

Share knowledge, make others good

The Kosan Crisplant Group

Compliance to regulations, standards, and instructions

Standard symbols and annotations

Symbol Status Description

WARNING Mandatory/ critical safety instruction to prevent

NOTE A reference to an important information/ feature

Document title: Data Collector - V 2.03.00

Document status: Master/ Translation IFS No: XXXXXXX R0X

Revision track record

Revision Date Description

01 12.03.2001 Initial release

02 dd.mm.yyyy Update of user guide with a new format

Document Author : MIC/ VPA

2. Data Collection Monitor ...................................................................................4

5. How to set-up ................................................................................................ 12

Author : MIC/ VPA Revision Date : 16.07.2014 No : 01

- a user-friendly software application operated on a PC.

1.1 System features

- select the required data network/ channels.

- view the data flow status, in a given data network/ channel.

- save the report(s).

- print the report(s).

1.2 How to use the application

- Ask for assistance, in case of a doubt

To use the application

1 Start the PC and open the Data Collector Monitor [B].

2 Navigate to the required status information window(s).

Author : MIC/ VPA Revision Date : 16.07.2014 No : 01

The application icon is Data

- the layout of the plant and its

- the data transfer network(s).

The interactive graphical user

- section 2 for information on

- section 3 for information on

- section 4 for information on

Figure 1.1 Basic monitoring steps

Author : MIC/ VPA Revision Date : 16.07.2014 No : 01

Data Collection Monitor

2. Data Collection Monitor

- is a dynamic user interface.

- provides the data network layout.

- allows the operator to access the relevant information.

Figure 2.1 Data Collection Monitor

Author : MIC/ VPA Revision Date : 16.07.2014 No : 01

Data Collection Monitor

Functionality bar (b1)

Press the icon to open up the Setting option.

Press the icon to minimize the application.

Press the icon to close the application.

Plant group bar (b2)

System group bar (b3)

Network monitor bar (b4)

Friendly Name used for the given network

Message Number of messges received by the given Network Monitor.

Monitoring Operating status of a given data network channel as described below:

Network monitor bar (b4)

The bar with the data queue status.

TCP Queue Amount of data awaiting to be sent via TCP

Table 2.1 Data Collection Monitor

Author : MIC/ VPA Revision Date : 16.07.2014 No : 01

2. Data Collection Monitor ...................................................................................4

5. How to set-up  ................................................................................................ 12

- the layout of the plant and its

- section 2 for information on

- section 3 for information on

- section 4 for information on

3 Save the new settings with the Save button e8.