GE Industrial Solutions POWER LEADER PMCS Network Architecture User Manual

g
GEH-6502
POWER LEADER™
Power Management Control System
Network Architecture Guide
WARNINGS
CAUTIONS
GEH-6502
WARNINGS, CAUTIONS, AND NOTES
Warning notices are used in this publication to emphasize that hazardous voltages, currents, or other conditions that could cause personal injury exist in this equipment or may be associated with its use.
Warning notices are also used for situations in which inattention or lack of equipment knowledge could cause either personal injury or damage to equipment.
Caution notices are used for situations in which equipment might be damaged if care is not taken or which may cause communication errors to occur.
NOTES
Notes call attention to information that is especially significant to understanding and operating the equipment.
This document is based on information available at the time of its publication. While efforts have been made to ensure accuracy, the information contained herein does not cover all details or variations in hardware and software, nor does it provide for every pos­sible contingency in connection with installation, operation, and maintenance. Features may be described herein that are not present in all hardware and software systems. GE Industrial Systems assumes no obligation of notice to holders of this document with respect to changes subsequently made.
GE Industrial Systems makes no representation or warranty, expressed, implied, or statutory, with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warrantees of merchantability or fitness for purpose shall apply.
©Copyright 2000- 2002 GE Company, all rights reserved.
POWER LEADER™, MicroVersaTrip®, Spectra®, and PowerBreak® are trademarks of GE Company.
®
Modbus RTU Modbus
is a registered trademark of AEG Schneider Automation.
®
is a registered trademark of Modicon Inc.
Power Management Control System
This manual provides an overview of the network architecture associated with the GE POWER LEADER Power Management Control System (PMCS). Please read through this guide prior to laying out a PMCS network. You must comple te the following steps before proceeding with the instructions in this manual:
1. Have instruction manuals on hand for all Intelligent Electronic Devices (IEDs) to be installed. (See Ap pe ndix B f or a list of in str uction manuals.)
2. Complete installation of all system IEDs.
• All IEDs mounted.
• All IEDs wired to cont rol power and energize d .
• All IEDs assigned a unique address. Refer to the appropriate IED instruction manuals
for these procedures.
3. Ensure that the PC serving as the Power Management Contro l S y stem host is operati onal:
• The RS-485 interface card, RS-232/RS-485
converter, or Ethernet Card is installed and functioning correctly.
• Any Ethernet Gateways or Modbus
Concentrators are installed and functioning correctly.
• Windows 2000 SP2 is installed and functioning
correctly.
• The Power Management Control System
software is installed and properly configured.
Getting Started
WARNING: Where personnel or equipment safety is involved, do not rely exclusively on information reported by the Power Management Control System or any power management equipment. ALWAYS confirm the status and safety of electrical power equipment in person by conventional test IEDs before operating, energizing or working on such equipment.
WARNING: Network wiring and grounding rules described herein apply primarily to commercial/industrial installations. Substation installations will exist in the presence of dangerously elevated ground potential relative to points outside of the station grid as well as large electromagnetic induction fields. Additionally, large ground faults can elevate substation ground potentials. Follow local utility best-practices/safety procedures to prevent risk of shock/electrocution to personnel and damage to equipment that could result in a loss of protection and communications.
Power Management Control System
Getting Started
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Power Management Control System
Table of Contents
Preface
Welcome to PMCS!.............................................................................................................................................1
What is Power Management?............................................................................................................................1
Benefits of Power Management.........................................................................................................................1
What is PMCS? ...................................................................................................................................................1
How Does PMCS Work? .....................................................................................................................................2
Using This Guide .................................................................................................................................................2
Chapter 1 – Introduction................................................................................. 3
1–1 Typical Systems...........................................................................................................................................3
1–2 Master-Slave Organization .........................................................................................................................4
1–3 Required Hardware......................................................................................................................................5
Host Computer......................................................................................................................................5
RS-485 Interface Card or RS-232/RS-485 Converter..........................................................................5
Ethernet Network Card........................................................................................................................5
1–4 Compatibility & Interconnection with Existing Ethernet Networks...........................................................5
1–5 Operation During Power Outage.................................................................................................................5
1–6 Time & Date Stamping................................................................................................................................6
1–7 Remote System Operation...........................................................................................................................6
1–8 Supported IEDs ............................................................................................................................................7
Chapter 2 – Network Design...........................................................................9
2–1 Modbus Rules............................................................................................................................................10
2–2 Ethernet Configuration Rules....................................................................................................................11
Table 3. Ethernet configuration rules2–3 Ethernet Network Considerations ................................................12
10Base-T specifications and rules ....................................................................................................13
10Base-FL specifications and rules...................................................................................................13
2–4 Commnet Configuration Rules...................................................................................................................14
2–5 Modbus Wiring Rules – Diagrams............................................................................................................15
2–6 Commnet Wiring Rules – Diagrams..........................................................................................................19
2–7 Performance Recommendations...............................................................................................................21
The Ideal Network..............................................................................................................................21
Modbus performance recommendations..........................................................................................21
Commnet performance recommendations........................................................................................21
2–8 Addressing the IEDs...................................................................................................................................21
2–9 Multiple RS-485 Networks – Addressing.................................................................................................25
2–10 System Expansion....................................................................................................................................25
2–11 Case Studies............................................................................................................................................25
Case Study One..................................................................................................................................25
Case Two............................................................................................................................................27
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Power Management Control System
Table of Contents
Case Three.........................................................................................................................................29
Case Four............................................................................................................................................30
Case Five............................................................................................................................................33
Chapter 3. Network Wiring and Construction.............................................37
3–1 Wiring Requirements................................................................................................................................38
Type of Wire ......................................................................................................................................39
Termination........................................................................................................................................39
Shield Grounding ...............................................................................................................................39
3–2 Modbus – Commnet Integration...............................................................................................................39
Wiring Concerns ................................................................................................................................39
3–3 Modbus – Ethernet Integration ................................................................................................................41
3–4 Local Configuration of IEDs.......................................................................................................................41
3–5 Applying Power to the System..................................................................................................................41
3–6 Software Loading and Startup..................................................................................................................41
Chapter 4 –Trouble-Shooting........................................................................42
4–1 Communication Network Trouble-Shooting.............................................................................................42
4–2 Host Trouble-Shooting..............................................................................................................................43
4–3 IED Trouble-Shooting................................................................................................................................43
4–4 Equipment Trouble-Shooting ....................................................................................................................43
4–5 Product Service Procedure........................................................................................................................43
4–6 Trouble-Shooting Guide............................................................................................................................44
Overview...........................................................................................................................................................49
239 Motor Protection Relay..............................................................................................................................49
269+ Motor Management Relay......................................................................................................................49
565 Feeder Management Relay.......................................................................................................................50
735 Feeder Relay..............................................................................................................................................50
MX200 (Microprocessor Controller).................................................................................................................51
Generator PLC (Series 90-70)...........................................................................................................................51
Electronic Power Meter EPM 7330.................................................................................................................. 51
Electronic Power Meter EPM 3710.................................................................................................................. 52
Electronic Power Meter EPM 3720.................................................................................................................. 53
Electronic Power Meter EPM 7300.................................................................................................................. 53
Electronic Power Meter EPM 7500/7600/7700 ..............................................................................................53
GE Fanuc PLC 90/30..........................................................................................................................................54
GE Fanuc PLC 90/70..........................................................................................................................................54
GE Fanuc PLC Micro 90.....................................................................................................................................54
EPM 5000P/5200P/5300P/5350P.....................................................................................................................54
MicroVersaTrip-C and -D and Spectra MicroVersaTrip Trip Units.................................................................55
Modbus Concentrator.......................................................................................................................................55
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Table of Contents
Electronic Power Meter (PLEPM)......................................................................................................................55
POWER LEADER Ethernet Gateway .................................................................................................................56
POWER LEADER Junction/Outlet Box..............................................................................................................56
POWER LEADER MDP Overcurrent Relay........................................................................................................56
POWER LEADER Meter.....................................................................................................................................56
POWER LEADER Modbus Monitor....................................................................................................................57
POWER LEADER Repeater................................................................................................................................57
Power Quality Meter (PQM)..............................................................................................................................57
RS-485 Repeater...............................................................................................................................................58
Spectra Electronic Control Module (ECM)........................................................................................................58
SR469 Motor Management Relay....................................................................................................................58
SR489 Generator Management Relay..............................................................................................................59
SR745 Transformer Management Relay..........................................................................................................60
SR750 Feeder Management Relay...................................................................................................................60
SR760 Feeder Management Relay...................................................................................................................61
Motor Manager II (MMII)..................................................................................................................................61
90/30 and 90/70 PLCs.......................................................................................................................................66
Micro 90 PLC .....................................................................................................................................................66
Connect Tech RS-485 card................................................................................................................................67
Ethernet Gateway .............................................................................................................................................67
Appendix A. IED Descriptions Appendix B. Reference Documents Appendix C. Special Wir i ng Considerations
iii
Power Management Control System
List of Figures and Tables
Figures
Figure 1. Modbus-only network...................................................................................................................................................................3
Figure 2. Commercial Ethernet and Modbus network.................................................................................................................................3
Figure 3. Modbus and commnet network....................................................................................................................................................4
Figure 4. Ethernet, Modbus, and commnet network...................................................................................................................................4
Figure 5. Ethernet-based host services Ethernet, Modbus, and commnet networks................................................................................4
Figure 6. Example of remote operation using modems...............................................................................................................................6
Figure 7. Network illustrating Modbus Rules 1 and 2. .............................................................................................................................15
Figure 8. Network illustrating Modbus Rule 3. .........................................................................................................................................15
Figure 9. Network illustrating Modbus Rules 4 and 5. .............................................................................................................................16
Figure 10. Network illustrating Modbus Rule 6. .......................................................................................................................................17
Figure 11. Network illustrating Modbus Rule 7. .......................................................................................................................................17
Figure 12. Network illustrating Modbus Rule 8. .......................................................................................................................................17
Figure 13. Network illustrating Modbus Rule 9. .......................................................................................................................................17
Figure 14. Valid Modbus Monitor network architectures.........................................................................................................................18
Figure 15. Network illustrating commnet Rule 1.......................................................................................................................................19
Figure 16. Network illustrating commnet Rule 2.......................................................................................................................................19
Figure 17. Network illustrating commnet Rule 3.......................................................................................................................................19
Figure 18. Network illustrating commnet Rule 4.......................................................................................................................................19
Figure 19. Network illustrating commnet Rule 6.......................................................................................................................................20
Figure 20. Network illustrating commnet Rule 6.......................................................................................................................................20
Figure 21. Sample network with IED addresses........................................................................................................................................23
Figure 22. Floor layout for Case One..........................................................................................................................................................26
Figure 23. Redesigned layout for Case One. .............................................................................................................................................26
Figure 24. Floor layout for Case Two.........................................................................................................................................................28
Figure 25. Floor layout for Case Three.......................................................................................................................................................29
Figure 26. Floor layout for Case Four.........................................................................................................................................................31
Figure 27. Floor layout for Case Five..........................................................................................................................................................33
Figure 28. Commnet shield grounding wired correctly. ............................................................................................................................40
Figure 29. Incorrect wiring. Looping on one Modbus Concentrator commnet port.................................................................................40
Figure 30. Incorrect wiring. Looping to two Modbus Concentrator commnet ports................................................................................40
Figure 31. Incorrect wiring. Looping on segment connected to Junction Box. ........................................................................................40
Figure 32. Incorrect wiring. Looping on segment connected to POWER LEADER Repeater. ..................................................................40
Tables
Table 1. IEDs supported by PMCS................................................................................................................................................................8
Table 2. Host PC configuration rules..........................................................................................................................................................10
Table 3. Ethernet configuration rules. .......................................................................................................................................................12
Table 4. Commnet IED configuration rules................................................................................................................................................14
Table 5. Modbus address range appropriate usage.................................................................................................................................22
Table 6. Modbus-to-commnet address mapping.......................................................................................................................................22
Table 7. IED-addressing scheme for Figure 21..........................................................................................................................................24
Table 8. IED Addresses for Case One........................................................................................................................................................26
Table 9. IED Addresses for Case Two........................................................................................................................................................28
Table 10. IED Addresses for Case Three...................................................................................................................................................30
Table 11. IED Addresses for Case Four......................................................................................................................................................32
Table 12. IED Addresses for Case Five......................................................................................................................................................34
Table 13. Wiring requirements..................................................................................................................................................................38
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Power Management Control System
List of Figures and Tables
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Power Management Control System
Preface

Welcome to PMCS!

Hello and welcome to POWER LEADER Power Management Control System (PMCS). You are about to begin using your computer in an exciting new way: as a tool to help you increase productivity and reduce downtime and energy costs through power management.

What is Power Management?

Inside every switchgear lineup, switchboard, panelboard, and motor control center flows a vast amount of information that can save and even make you money. The data is in the form of power (volts, amperes, and their time-dependent waveforms) that passes through the equipment every second of every hour of every day. With the proper IEDs, you can selectively access this wealth of information and use it to b ecome more efficie nt and more productive. Your power distribution equipment can go beyond its fun dame ntal pr otection rol e to be come a p rof it­generating asset. This is what power management systems are all about.

Benefits of Power Management

A power management system provides the tools to control energy costs, minimize downtime and outages, and optimize operation to increase productivity. With such a system in place, you can benefit from:
Less downtime – Identify and correct problems before
they lead to loss of power and/or costly damage to loads such as production equipment and computers.
Reduced energy costs – Find ways to conserve power,
correct billing errors, reduce peak usage surcharges, and leverage interruptible rates.
Improved predictive maintenance – Identify simple
maintenance tasks so you can make scheduled corrections before they become problems.
Faster corrective maintenance – Quickly pinpoint the
root causes of problems using tools such as time­tagged alarms, sequence of events logs, and triggered waveform capture conditions.
Increased safety – Provide a centralized source of
information, reducing the need for physical contact with equipment and shop-floor or sub-station presence.
Higher productivity – Free up maintenance and repair
personnel to perform other needed duties.
Improved power quality – Identify sources of “dirty”
power, otherwise invisible, and take corrective action
to save wear, tear, and possible damage to critical production equipment and other loads.
It should come as no surprise that approximately half of all switchgear is now shipped with power management features. What began as an option is fast becoming an absolute necessity for efficient facility management and increased profitability.

What is PMCS?

PMCS is the latest Power Management Control software from GE Industrial Systems’ robust line of POWER LEADER power management products. PMCS seamlessly integrates with the comprehensive family of POWER LEADER IEDs as well as with many new Modbus RTU and Ethernet IEDs and systems.
The Power Management Control System supplies the power-system information you need to optimize usage and minimize power cost and downtime.
Its state-of-the-art graphical interface is easy to use, with the ability to view systems from both the physical and electrical perspectives. Additional features include:
• Viewing metering information at remote locations.
• Historical trending of any metered data.
• Tracking the status of protective and metering IEDs.
• Alarm and event management.
• Report generation.
• Waveform capture and analysis.
• Remote control of IEDs.
• Remote configuration of IEDs.
Interaction with Cost Allocation software to provide
facility energy and demand data.
The Power Management Control System accomplishes these tasks through a networ k of attached IEDs th at serve to protect equipment and collect and transmit data.
These IEDs include trip units, metering IEDs, protective relaying IEDs, and others. They communicate on either the POWER LEADER communication network (commnet), Modbus RTU commu nications p rotocols, OR Ethernet to transmit data to the PMCS software.
You can operate PMCS software from either a PC running directly on the Modbus platfor m or from a PC connected to an Ethernet network, which is linked to the Modbus network via the POWER LEADER Ethernet Gateway. (Some devices, such as the EPM 7700, communicate directly over an Ethernet network and do not require an Ethernet Gateway.)
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Power Management Control System
Preface

How Does PMCS Work?

The PMCS software runs on a PC (called the host). The host is linked to the power management IEDs through a network (RS-485), and speaks to them using the Modbus RTU communications protocol piece of software called the PMCS Network and IED Configurator. The Network and IED Configurator is a Dynamic Data Exchange Server (we’ll refer to it as the PMCS DDE Server or simply the Server). It responds to requests for data from other software packages called clients. When the PMCS DDE Server receives a request for data from a client, it sends a message out to the appropriate IED requesting the data. Each piece of data is called a tag. The PMCS DDE Server polls the appropriate tags (or blocks of tags) f rom eac h IED an d pa sses the data back to the client which requested it. The Server then begins to monitor that tag; if it cha nge s, th e Ser ve r n otifies the client that had previousl y req uested th e data; th us, n ot only is the cur rent request an swered, but th e client is also kept informed of l a ter changes.
Some power management IEDs are relatively simple and keep track of only a few power characteristics or events; they require only a few tags at the DDE Server. More sophisticated IEDs keep track of many more pieces of information, requiring a greater portion of the DDE Server’s resources.
The limit on the number of IEDs that can be managed by the PMCS varies from network to network and is a function of the kind and sophistication of the IEDs that the DDE Server is tracking. Obviously, the more sophisticated the IEDs and the greater the demands they place on the DDE Server, the fewer IEDs that may be ma naged.
1
. The heart of PMCS is a

Using This Guide

This manual is a simp le an d d irec t guide to des ignin g a nd connecting a power management system based on GE’s Power Management Control System. Please read the entire manual before attempting to put it into practice.
Chapter 1 provides a basic overview of the PMCS: typical systems and intelligent electronic devices (IEDs) supported. It is imperative that you have a thorough understanding of what the PMCS is and its various components before you read the rest of this book.
Chapter 2 discusses the rules and requirements for designing the netw ork on paper: how far apart IEDs may be located, address ing the IEDs, limits on the number of IEDs. Chapter 2 also provides several case studies as examples of how to design a PMCS network that will fit your needs. After studying this chapter and the case studies, you should understand how to lay out networks based on PMCS.
Chapter 3 explains the details of actual network construction: types of wire required, ter mination resistors, how to wire IEDs together. Actual connection details are given in the user manuals of each individual IED, which you should refer to directly.
Chapter 4 offers information on operations and trouble­shooting. The infor mation pr ovid ed h ere w ill he lp you ge t your system up and running and keep it that way!
Several Appendices offer more detailed descriptions of PMCS-compatible IEDs and a list of reference publications.
The host is networ ked to the power management IED s in one of two fashions. The host may be base d directly on the RS-485 platform and communicate with the RS-485 networks via interface cards. Alternatively, the host may reside on an Ethernet network, talking directly to Ethernet-capable IEDs such as the EPM 7700, and to Modbus-native devices via a separate Modbus-to-Ethernet converter which supports the RS-485 networks. This is described in greater detail later in the manual.
1
EPM 7700 devices are the exception; instead of using Modbus, they
communicate directly over E t hernet.
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Power Management Control System

Chapter 1 – Introduction

Chapter 1 – Introduction

1–1 Typical Systems

The PMCS software is capable of operating on either of two platforms:
1. PMCS running on a Modbus-based host PC, or
2. PMCS running on an Ethernet-based host PC.
Determine where the PMCS will be based using the following flowchart:
Should I base my host PC on Modbus or Ethernet?
Is there an existing
Ethernet or
plans for a
future Ethernet?
No
Base PMCS on Modbus.
Figure 2 shows a Modbus and Et he rne t network. Figure 3 shows a Modbus/commnet network. Figure 4 shows an Ethernet/Modbus/commnet network,
demonstrating the integration of all three protocols. Figure 5 shows an example of an Ethernet-based host
servicing native Ethernet devices, Modbus devices via the Ethernet Gateway, and Commnet devices via the Modbus Concentrator device.
NOTE: Some types of IEDs must be wired on dedicated private serial network segments, one IED per serial Modbus line. Figure 2a illustrates this configuration. The IEDs that require dedicated Modbus segments are the EPM 9650Q, EPM 3720, ML PQM, and EPM 7330.
Yes
Base PMCS on Ether net.
After you determine the appropriate base (Ethernet or Modbus) for the PMCS software, the general network architecture will fall into one of the forms illustrated in Figures 1 through 4. These figures offer samples of various network architecture configurations possible with PMCS.
Protocols Utilized
Ethernet
Direct
Modbus
via
Modbus
Direct
Commnet
Ethernet
Figure 1 Figure 2 Figure 3 Figure 4 Figure 5
üü
üü ü
üü ü ü
ü
üü
As the above table shows, Modbus RTU is required in all instances, whether it is being used as a stand-alone network, supporting commnet IEDs, or serving as a slave to an Ethernet-based host.
Figure 1. Modbus-only network.
EPM 3720
other
PC
M u ltilin
269+
...
...
...
...
Ethernet
Modbus
M ult ilin
565
PLC
90/70
Host
Ethernet
Gateway
PLC
90/30
Figure 2. Commercial Ethernet and Modbus network.
Figure 1 presents the Power Management Control System operating on a Modbus-only network.
3
Power Management Control System
Chapter 1 – Introduction
Figure 2a. Substation Ethernet and Modbus network.
Figure 5. Ethernet-based host services Ethernet, Modbus,
and commnet networks.
Figure 3. Modbus and commnet network.
other
PC
EPM
3720
Mu lt ilin
269+
PLC
90/30
...
...
...
Ethernet
...
Modbus
Host
Commnet
Comm net device s
Ethernet Gateway
Modbus
Concentrator
Figure 4. Ethernet, Modbus, and commnet network.

1–2 Master-Slave Organization

The PMCS in either a Modbus-host or an Ethernet-host configuration is a master-slave network. The host is considered to be the ma ster, with the a ttached n etwor ks of IEDs serving as its slaves.
This relationship means that the communications are always initiated a t the host; an IED wil l not speak without being asked to. The master requests information, the slave replies.
The PMCS DDE Server receives a request from a client application for some data, perhaps a relay waveform capture. The Server routes the request to the correct IED, the IED replies to the Server, and the Server passes the information back to the client that originally requested it.
For further details, refer to the PMCS Network and Device Configurator DDE Server User’s Guide, GEH-6510.
4
Power Management Control System
Chapter 1 – Introduction

1–3 Required Hardware

Several pieces of hardware are required to build a network based on PMCS. They are the host computer and the network interf ace card, each of whic h is described b elow. Once the host computer is op era ting a nd its inte rf ace car d is installed, it is time to attach the power management IEDs to the network. These IEDs are described in Section 1–8.

Host Computer

The heart of the PMCS is software running on a host PC. Regardless of whether the host PC is based on an Ethernet or Modbus network, its functions include the following:
• Communication management
• Primary user interface
• Data collection, storage, and retrieval
• Event reporting with time and date stamp
• Energy calculations and trending
•Network IED status
• Alarming and repo rting
The minimum requirements for the host PC are presented in GEH-6514, Read This Book Fir s t .
The communications interface is the connection between the host PC and the network of IEDs. Your host will require either an Ethernet communications card, an RS­485 communications card, or an RS-232/RS-485 converter. An Ethernet-based host PC requires an Ethernet network card. A Modbus-based host PC requires an RS-485 interface card or an RS-232/RS-485 converter. These are described below.

RS-485 Interface Card or RS-232/RS-485 Converter

The RS-485 interface card provides the interface between the host PC and the Modbus network and ter minates the network at the host computer. This standard RS-485 interface card provides eight RS-485 ports. PMCS supports up to 256 RS-485 communication ports. See Sections 2–1, 2–4, and 2–7 for more details on using multiple RS-485 networks with PMCS.

Ethernet Network Card

The Ethernet network card provides the interface between the host PC and the Ethernet network. With the host communicating over Ethernet, another interface is required to communicate with RS-485 networks, where most power management IEDs reside. (Some recent power management IEDs, such as the EPM 7700, have built-in Ethernet capability. Install these devices using standard Ethernet networking procedures.)
This interface between Ethernet and RS-485 is provided by the Ethernet Gateway. See Section 1–4 for more information on Ethernet, and Section 1–1, Figures 2 and 4, for examples of how the Ethernet Gateway is used to integrate RS-485 networks into the Ethernet network.

1–4 Compatibility & Interconnection with Existing Ethernet Networks

PMCS and the Ethernet Gateway require TCP/IP to be installed on the host computer. The drivers for the TCP/IP protocol are included with Windows 2000 SP2, which is required to run PMCS, so any customer running PMCS should have these drivers available.
Consult your LAN personnel or system integrator for information on integrating PMCS with an existing Ethernet-based netwo rk .

1–5 Operation During Power Outage

PMCS will not lose any data in the event of a power outage; however, communica tions will be interrupted u ntil power is restored.
Should control power to a Modbus Concentrator be lost, PMCS will be unable to c ommunicate with any commnet IEDs downstream from the Concentrator until power is restored. No data will be lost, but communications will be interrupted.
The same is true of the Ethernet Gateway; as the linchpin connecting the host to the network of IEDs, if a Gateway loses control power, the host will be unable to communicate with an y IEDs attached to th e Gateway until power is restored.
For more modest needs, a single RS-485 network can be provided by an RS-232/RS-485 converter, a self-contained IED that converts signals between RS-232 and RS-485. This IED plugs into the RS-232 port on the back of the host PC and is less expensive than an RS-485 i nterface card.
You can avoid this situation by providing uninter ruptable power supplies (UPS) to the host computer and by providing secure control power to the IEDs, either with UPS systems or battery backups (different IEDs have different requirements). Refer to individual user guides for information on control-power re q u irements.
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Power Management Control System
Chapter 1 – Introduction

1–6 Time & Date Stamping

PMCS stamps each event with a time and date code for precise reference. The time and date are set by the DDE Server and passed across the network to each IED, so that all IEDs are synchronized.
Additionally, some PMCS IEDs support IRIG time synchronization. If IRIG is used in a PMCS system, it is recommended that the host PC be IRIG time synched as well to maintain synchronization between the IEDs and the PMCS DDE Server.

1–7 Remote System Operation

PMCS also offers the ability to use modems to reach across wide areas to re mote facilities or substation s. For instance , you could use PMCS at a central location to collect power management data from IEDs in a factory, warehouse, or substation in another state or control the lights, air conditioning, or protective relays in your facility from across the country.
An example of this scenario is shown in Figure 5.
Host
...
RS-485 wiring
Radio Frequency transmission, Fiber optic conn e ct io n, Leased line or phone line connection
RS-485 wiring
Modbus
device
Modbus
device
RS-232/RS-485
Converter
RS-232 wiring
Modem
Modem
RS-232 wiring
RS-232/RS-485
Converter
Figure 6. Example of remote operation using modems.
56kbps phone modems, radio frequency (RF) modems, and fiber optic modems (FOM) may be used with PMCS.
While it is possible to use dial-up lines to connect to distant RS-485 networks, the vagaries of the phone system and the excessive long-distance charges preclude using this as a twenty-four-hour-a-day connection. Leased lines dedicated to this purpose provide a viable alternative to a constant long-distanc e telephone connect ion.
For further information on using modems for long-range operation of PMCS, contact your GE sales representative.
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Power Management Control System

1–8 Supported IEDs

PMCS supports a wide variety of GE and third-party power management IEDs. These IEDs are listed in Table 1, along with their function, communications
Chapter 1 – Introduction
protocol, and maximum communications speed for Modbus-based IEDs (Commnet IEDs must communicate through the Modbus Concentrator).
IED Name
IED Name
IED NameIED Name 239 Motor Protection Relay Protection/Control Modbus RTU (19.2 Kbaud) 269 Plus Motor Management Relay Protection/Control Modbus RTU (2400 baud) 565 Feeder Management Relay Protection/Control Modbus RTU (9600 baud) 735 Feeder Relay Protection/Control Modbus RTU (19.2 Kbaud) GE-Zenith Generator PLC (Series 90-70) Metering/Control Modbus RTU (19.2 Kbaud) GE-Zenith MX200 (Microprocessor Controller) Protection/Control Modbus RTU (19.2 Kbaud) EPM 7330 Metering Modbus RTU (19.2 Kbaud) EPM 3710 Meter Metering Modbus RTU (19.2 Kbaud) EPM 3720 Meter Metering Modbus RTU (19.2 Kbaud) EPM 7300 Meter Metering Modbus RTU (19.2 Kbaud) EPM 7700 Meter Metering/Control Modbus RTU (19.2 Kbaud)
EPM 5000P Meter Metering Modbus RTU (9600 baud) EPM 5200P Meter Metering Modbus RTU (9600 baud) EPM 5300P Meter Metering Modbus RTU (9600 baud) EPM 5350P Meter Metering Modbus TCP (Ethernet 10BaseT, RJ-45)
EPM 9450Q Meter Metering/Control Modbus RTU (38.4 Kbaud)
EPM 9650Q Meter Metering/Control Modbus RTU (38.4 Kbaud)
GE Fanuc PLC 90/30 Protection/Control Modbus RTU (19.2 Kbaud) GE Fanuc PLC 90/70 Protection/Control Modbus RTU (19.2 Kbaud) GE Fanuc PLC Micro 90 Protection/Control Modbus RTU (19.2 Kbaud) Universal Relay Protection/Control Modbus RTU (19.2 Kbaud) MicroVersaTrip-C and -D Trip Units Metering/Protection commnet (requires Modbus Concentrator) Modbus Concentrator Communications Modbus RTU (19.2 Kbaud) POWER LEADER Electronic Power Meter Metering Modbus (19.2 Kbaud) or commnet
POWER LEADER Junction Box Communications commnet (requires Modbus Concentrator) POWER LEADER Repeater Communication commnet (requires Modbus Concentrator) Power Quality Meter (PQM) Metering Modbus RTU (19. 2 Kbaud on 1 or 2 ports)
Function Communications Protocol (Modbus Speed)
Note: Native Ethernet device.
Modbus TCP (Ethernet 10BaseT, RJ-45)
Modbus TCP (Ethernet 10BaseT, RJ-45)
(commnet requires Modbus Concentrator)
7
Power Management Control System
Chapter 1 – Introduction
IED Name
IED Name
IED NameIED Name RS-485 Repeater Communications Modbus RTU (19.2 Kbaud) 369 Motor Management Relay Metering/Control Modbus RTU (19.2 Kbaud) EPM 7500 Electronic Power Meter Protection/Control Modbus RTU (19.2 Kbaud) EPM 7600 Electronic Power Meter Protection/Control Modbus RTU (19.2 Kbaud) Motor Manager II (MMII) Protection/Control Modbus RTU (19.2 Kbaud) EPM7430D/EPM7450D (Futura) Protection/Control Modbus RTU ( 9600 baud) Spectra Electronic Control Module Protection commnet (requires Modbus Concentrator) Spectra MVT for GEK Frame MCCB Metering/Protection commnet (requires Modbus Concentrator) SR469 Motor Management Relay Protection/Control Modbus RTU (19.2 Kbaud on 1 or 2 ports) SR489 Generator Management Relay Protection/Control Modbus RTU (19.2 Kbaud on 1 or 2 ports) SR745 Transformer Management Relay Protection/Control Modbus RTU (19.2 Kbaud on 1 or 2 ports) SR750 Feeder Management Relay Protection/Control Modbus RTU (19.2 Kbaud on 1 or 2 ports) SR760 Feeder Management Relay Protection/Control Modbus RTU (19.2 Kbaud on 1 or 2 ports) POWER LEADER MDP Overcurrent Relay Protection Modbus (19.2 Kbaud) or commnet
POWER LEADER Modbus Monitor Monitoring Modbus RTU (19.2 Kbaud on 1 or 2 ports) POWER LEADER Meter Metering commnet (requires Modbus Concentrator)
Table 1. IEDs supported by PMCS.
Function Communications Protocol (Modbus Speed)
(commnet requires Modbus Concentrator)
2
2 The POWER LEADER Ethernet Gateway is not listed in Ta bl e 1. Th e Eth ern et Ga tewa y i s a n a l tern a te h o s t f o r th e RS-485 networks u sed when th e
PMCS resides on the Ethernet level.
8
Power Management Control System

Chapter 2 – Network Design

This section describes how to design a Power Management Control System network on paper so that actual construction and configuration of the network will proceed smoothly.
You need two things f or this exercis e: a complete list of the IEDs to be networked and a diagram or map of where the IEDs will be located, preferably with realistic distances noted so that wiring runs may be kept within the appropriate limits.
Using the list of IED s to be networked , refer to Table 1 and note which communications pr otocols are re quired (commnet or Modbus). For Modbus IEDs, note the communications speed at which each IED operates. For IEDs supporting both p rotocols, you will n eed to decide which protocol will be used. Generally, it is preferable to use Modbus rather than commnet unless the Modbus network is at or near capacity for physical IEDs.
Chapter 2 – Network Design
When the list of IEDs and the floor plan are in hand, proceed to Section 2–1 for network desi gn rules.
9
Power Management Control System
Chapter 2 – Network Design

2–1 Modbus Rules

The most basic network configuration for PMCS assumes that the software is running on a host PC supporting one or more RS-485 networks on the Modbus protocol. (See Figure 1 for an example of this configuration.)
Host PC is based on:
Modbus 1. The host PC can support
Follow these rules for the host… And these rules for the attached Modbus network(s)…
Each Modbus network supports up to 31 physical Modbus IEDs
1. up to 256 independent Modbus networks. The actual number is determined by the communication cards installed in the host PC (see below).
The Modbus networks are
2. connected to the host PC via an eight-port RS-485 communications card. An option for more limited systems is an RS­232/RS-485 converter, which permits a single RS­485 network.
4
3. The host PC must be located at one end of the Modbus network(s).
3
and up to 247 Modbus addresses. This is possible because commnet IEDs attached to Modbus Concentrators occupy Modbus addresses but do not create an electrical drain on the RS­485 network and thus are not counted as physical Modbus IEDs.
Each Modbus network must be properly terminated at each end
2. of the network. See Section 2–4.
3.
Maximum cable length of e a ch Modbus network is 4000 feet. (S e e
notes on using repeaters to increase this range, Section 2–4. Also, see the note regarding substation installation in Chapter 3.)
All Modbus IEDs attached to a si ngle RS-485 network must
4. communicate at the same baud rate. (See Table 1 for Modbus IEDs’ communication speeds.)
RS-485 cable shields must be properly g ro u nde d . Fo r maximum
5. protection against surge and EMI damage, each IED on the network should have an iso l at e d ground connectio n. S e e Section 2–4, Modbus rule 4, for an example of proper RS- 485 wiring and grounding. Also, see the note regarding substation installation in Chapter 3.
Table 2 explains the configuration rules for PMCS networks based on the Modbu s platform. Commnet IEDs may be integrated through the Modbus Concentr ator ( see Table 4 for commnet wiring rules).
Table 2. Host PC configuration rules.
3
The following RS-485 interf ace card is recommended for pro viding the RS-485 c onnection at th e host PC. If any o ther serial card i s used, PMCS requires that the communications driver be compatible with the MS Windows seri al communications proto col. Please refer to Section 3–1 fo r information on the special termination requirements of the RS-485 card.
Manufacturer Description Quantity/8 ports Part, Order Number
Connect Tech, Inc. Intellicon-Flex8 RS-485 card 1 I4808064XXNC
4
The following RS-232/RS-485 converter is recommended for providing a single RS-485 connection at the host PC.
Manufacturer Description Part, Order Number
Multilin RS-485/RS-232 Converter F485120
When using the above R S - 232/R S - 485 converter, remember that the con verter h a s D IP s wi tc h es inside that determine its ba u d rate. Switch group 3 should be set according to the baud rate at which the converter is to be used. Refer to the converter’s documentation for further information.
Intellicon/DFLEX SLIM 4 SIMMS 8 Port, DB9 I/O Box 1 IOB08DB9
10

2–2 Ethernet Configuration Rules

Power Management Control System
Chapter 2 – Network Design
It is also possible to run the PMCS on a host PC operating on an Ethernet network. If PMCS is running on an Ethernet-based PC, an Ethernet Gateway is required to communicate with the attac hed Modbus networ k(s). (See Figure 2 for an example of this configuration.)
Recently, IEDs with built-in Ethernet support have begun to become available; PMCS is also capable of supporting these devices. Examples of such devices are the EPM 7700 meter and EPM 9450Q / 9650Q meters. These devices reside on the Ethernet network at the same level as the Ethernet Gateway.
Table 3 explains the configuration rules for PMCS networks based on the Ethernet platform. Commnet IEDs may be integrated through the Modbus Concentrator. (See Table 4 for commnet wiring rules.)
EPM 7700 devices require a separate network configuration beyond connecting the devices to the Ethernet LAN. Please refer to the following PMCS technical documentation for complete network configuration rules and guidelines:
GEH-6514, PMCS Read-This-Book -First. Refer to the section titled “Configuring the EPM 7700 De vice Network.”
DEH-40035, GE 7700 Gateway User’s Guide. Refer to the section tit l e d “EPM 7700 Network Config uration.”
EPM9450Q and EPM9650Q devices require separate network configuration beyond connecting the devices to the Ethernet LAN. Refer to the instruction manuals of these devices a nd to the sections titled “Inter nal Network Option.” Also refer to DEH-6510, DDE Server User’s Guide. Refer to the sections describing the use and configuration of the Modbus TCP Server.
11
Power Management Control System
Chapter 2 – Network Design
Host PC is based on: Follow these rules for the host…
Ethernet 1. Ethernet Gateway(s) must be used to
communicate with non-Ethernet IEDs. Ethernet-capable IEDs may be installed directly on the Ethernet network at t he same level as the Ethernet Gateway(s).
The host PC supports up to 64 Ethernet
2. Gateways.
3.
Each Ethernet Gateway supports up to
four independent Modbus networks. The EPM 9450Q /9650Q devices wi ll support one Modbus network.
The actual number of IEDs supported
4. by the host varies from system t o system, depending on the variety of IEDs used and the number of PMCS data tags required by the IEDs. See GEH-6509, PMCS DDE Interface Guide, for details.
Ethernet networks should conform to
5. the design guidelines described in Section 2-3.

Table 3. Ethernet configuration rules2–3 Ethernet Network Considerations

And these rules for the Modbus networks attached to the Ethernet Gateways…
Each Modbus network supports up to 31 physic al
1. Modbus IEDs and up to 247 Modbus addresses. This is possible because commnet IEDs attached to Modbus Concentrators occupy Modbus addresses but are not seen as physical Modbus IEDs.
Each Modbus network must be properly terminated
2.
at each end of the network. See Section 2–4.
3.
The Ethernet Gateway must be located at one end of
the Modbus network(s).
4.
Maximum cable length of each Modbus network is
4000 feet. (See notes o n using repeaters to increa se this range, Section 2–4. Also, see the note regarding substation installation in Chapter 3.)
All Modbus IEDs attached to a single RS-485
5.
network must communicate at the same baud rate. (See Table 1 for Modbus IEDs’ communication speeds.)
RS-485 cable shields must be properly gro u nd ed . Fo r
6.
maximum protection against surge and EMI damage, each IED on the network should have an isolated grou nd c onnection. See S e c tion 2–4, Modbus rule 4, for an example of proper RS-485 wiring and grounding. Also, see the no te regarding substation installation in Chapter 3.
This section describes some of the specifications which must be considered when designing an Ethernet network to be used with PMCS.
Note: These specifications are guidelines only and should not be used for actual network design. Consult with a qualified LAN engineer for design requirements that meet your specific installation. The complete specifications are listed in IEEE 802.3 Ethernet. In addition, the National Electrical Code (NEC) and all applicable local codes must be followed for installing wiring.
Ethernet supports four physical media: 10Base-2 (thinnet), 10Base-5 (thicknet), 10Base-T (twisted pair), and 10Base-FL (fiber). 10Base-T is most common.
12
Power Management Control System
Chapter 2 – Network Design
NOTE for EPM 7700 and 9450Q and 9650Q: The EPM 7700 with Xpress card directly uses either of two types of Ethernet physical media that must be specified when ordering the meter, 10Base-T, or 10Base-FL. EPM 9450Q and EPM 9650Q must be ordered with 10 Base-T Ethernet Option. The meters operate in a 10 Mbps system.
10Base-T is specified when twisted pair is used and 10Base­FL is specified where fiber optic cable is used. While media converters are available to allow the use of both twisted pair and fiber optic cable in the same LAN, and can be used to extend the length of the LAN, th ey ar e bey ond the scope of this discussion.
CAUTION: The recommended installation practice is to implement optical fiber for connections between buildings to provide electrical isolation. This eliminates harmful ground loops caused by differences in the ground potenti a l be tween structures.
CAUTION: Data line surge protection is recommended for network components such as hubs, computers, or modems connected to IEDs with copper wire, especially installations where the data communication cable is exposed (i.e., not encased in conduit) or runs parallel to power conductors. PMCS IED s ar e r outinel y in stal led in areas exposed to heavy electromagnetic fields (EMF), which can induce damaging surges in data communication lines. Data line surge protection is not required for fiber optic connections.
A 10Base-T LAN can have a maximum of 1024 devices connected.
Use of repeaters, routers, bridges, gateways, etc. Repeaters may be used to connect LAN segments and do
not determine the boundaries of the LAN. They are used to extend the LAN beyond a single segment. Routers, bridges and gate ways may be used to conn ect the LAN to other LANs or to a WAN.

10Base-FL specifications and rules

Maximum/Minimum length of segments For a 10Base-FL LAN, the maximum length of a segment is
2000 meters (6500 ft). The minimum length of any cable is 2.5 Meters or about 8 ft. This minimum length is of particular concern when a device is located in close proximity to the hub.
Maximum number of segments A 10Base-FL LAN ca n consist of up to 5 s egments using 4
repeaters. However, only three of these segments can have devices connected.
Maximum number of devices A 10Base-FL LAN can have a maximum of 1024 devices
connected. Use of repeaters, routers, bridges, gateways, etc. Repeaters may be used to connect segments and do not
determine the boundaries of the LAN. They are used to extend the LAN beyond a single segment. Routers, bridges and gateways may be used to connect the LAN to other LANs or to a WAN.

10Base-T specifications and rules

10Base-T Ethernet uses CAT 3, 4 or 5 twisted pair cable, depending on the installation.
Maximum/Minimum length of segments For a 10Base-T LAN, the maximum length of a segment is
100 meters (328 ft). The minimum length of any cable is
2.5 Meters or about 8 ft. This minimum length is of particular concern when a device is located in close proximity to the hub.
Maximum number of segments A 10Base-T LAN can consist of up to 5 segments using 4
repeaters. However, only three of these segments can have devices connected.
Maximum number of devices
13
Power Management Control System
Chapter 2 – Network Design

2–4 Commnet Configuration Rules

POWER LEADER commnet IEDs may be integrated into a PMCS network through a special Modbus IED called the Modbus Concentrator. The rules outlined in Table 4 apply to using commnet IEDs with PMCS, regardl ess of whether the host PC is operating on an Ethernet or Modbus network. (See Figures 3 and 4 for examples of commnet IEDs operating on PMCS.)
Rules regarding: Commnet IED configuration rules:
Modbus Concentrator limitations
Commnet wiring limitations
1. Each Modbus Concentrator supports up to eight commnet segments.
2.
Each commnet segment supports up to four commnet IEDs.
3.
Only one waveform-capturing meter (POWER LEADER Meter) is allowed per
commnet segment.
4.
POWER LEADER Repeaters and Junction/Outlet Boxes do not count toward the
four-IED-per-segment limit.
5.
No connections between commnet segments are permitted. Each segment must
be wired independently (having no contact with other commnet segments) and connected to the Concentrator at one point only (no loops permitted).
1. Maximum cable length o f a commnet segment is 1000 fe e t. Maximum range
between commnet IEDs o n a se g ment is 1000 feet (except for repeaters; see below).
In no case may a commnet IED be wired more than 1000 feet fro m the Modbus
2. Concentrator or a POWER LEADER Repeater.
3.
POWER LEADER Repeaters may be used to extend the range of commnet
segments. A repeater regenerates t he co m m net signal to its origi nal st reng th, allowing it to t ravel up to another 1000 feet.
Long-distance segments may be created by placing multiple repeaters adjacent to
4. one another in a commnet segment. A repeater communicating directly with another repeater may span up to 6000 fe e t .
Maximum allowable cable length of a si ngle commnet segment i s 12,000 fe et,
5. which may be constructed with any allowable combination of repeaters and IEDs.
6.
For ease and economy of wiring, the POWER LEADER Junction/Outlet box may
be used to create nodes of commnet IEDs with a common wiring point to be connected to the Modbus concentrator. The POWER LEADER Junction/Outlet Box allows the interconnection of as many as four shielded, twisted-pair cables to create this common wiring point. For instance, rather than a daisy-chain of wiring in a lineup from one meter or trip unit to the next, up to four IEDs may be wired to the POWER LEADER Junction/Outlet Box, which is then connected to the Modbus Concentrator.
Reference Figure:
Figure 15 Figure 15 No figure
provided
Figure 19 and Figure 20
Figure 28 – Figure 32
Figure 16
Figure 16
Figure 17
Figure 18
No figure provided
Figure 19 and Figure 20
Table 4. Commnet IED configuration rules.
14
Power Management Control System
Chapter 2 – Network Design

2–5 Modbus Wiring Rules – Diagrams

The Modbus network protocol ha s wiring rules and limits on the number of IEDs that may be attached.
This section describes in greater detail the rules you must follow when designing a Modbus network.
WARNING: Network wiring and grounding rules described herein apply primarily to commercial/industrial installations. Substation installations will exist in the presence of dangerously elevated ground potential relative to points outside of th e station grid as we ll as large electromagnetic induction fields. Additionally, large ground faults can elevate substation ground potentials. Follow local utility best­practices/safety procedures to prevent risk of shock/electrocution to personnel and damage to equipment that could result in a loss of protection and communications.
NOTE: It is important to take future expandability into c ons ider ation wh en des ignin g a network configuration. This is particularly so when the network is near its maximum n umber of IEDs or maximum cable length. Adding IEDs
to a network after it has been installed may require rewiring the network.
1. Each RS-485 network may support up to 31 Modbus IEDs. Figure 7 illustrates this rule. (See the exception below Figure 6.)
Host
31 RS-485 IEDs maximum;
PMCS Ho s t PC, Ethernet G ateway or MSP
always located at one en d of Modbus network.
Figure 7. Network illustrating Modbus Rules 1 and 2.
Exception to Rule 1: Some types of IEDs must be wired on dedicated private serial network segments, one IED per serial Modbus li ne .
2. The host (or Ethernet Gateway) must always be located at one end of any Modbus segment. It may not be located in the center of a M odbus network. Figure 7 shows the correct placement of the host (PC or Ethernet Gateway).
3. All Modbus IEDs on a single RS-485 network must communicate at the same baud rate. If IEDs with different communication speeds are connected to the same RS-485 network, the whole segment will communicate at the speed of the slowest IED. Figure 8 illustrates this rule. (Communication speeds for supported IEDs are listed in Table 1.)
CAUTION: Wire-run distances mentioned in the configuration rules assume application above grade or in conduit. For below-grade applications, refer to Section 3–1, Wiring Requirements.
Regardless of which platform is supporting the RS-485 networks (Ethernet Gateway, RS-485 card, or RS-232/RS­485 converter), the following rules apply to each individual RS-485 network.
Figure 8. Network illustrating Modbus Rule 3.
4. Each RS-485 network must be properly terminated at both ends of the cable run after the final IED. (See Section 3–1 f or details on te rmination.) F igure 9 illustrates this rule.
15
Power Management Control System
Chapter 2 – Network Design
5. Each RS-485 network must have its shield properly grounded. Figure 9 illustrates proper RS-485 wiring and grounding.
CAUTION: Improper grounding may create a ground-loop condition and cause communications failures. Make sure you follow the wiring diag ram carefully.
To ensure proper grounding, follow this procedure. Begin by grounding the RS-485 cable shield at the host. Follow the cable to the first IED on the network. Do NOT conn ect the cable ground to the IED. Pick up the RS-485 output cable from the IED and attach its groun d to th e I E D’s shield con n e c tion or grounding screw. For IEDs with no grounding connectors, connect to earth ground.
Follow the cable to the next IED, and repeat the above procedure. Do not connect the RS-485 shield from the previous IED, but DO connect the RS-485 OUT shield on its way to the next IED.
EXCEPTION: The Multilin 565 Feeder Management Relay does not have isolated communications ports. Do NOT connect the shield at this IED. Instead connect the shield of the incoming RS-485 cable to the shield of the outgoing RS- 485 c a ble , sk ipping the Multili n 565.
Two wir e, twis ted, shielded pair cable
RS-485 IED #1
Shield
RS - 485 IED # 2
Shield
RS-485 Host
RS-485
+
-
+
-
(RS-485 c a rd* , RS232/RS-485 converter ,
Multiple Serial P o rt o r Ethernet Gateway RS -485 port)
Network Connections: + - Shield
Shield
connected
at host
120-ohm terminating resistor * Con ne ct Tech RS-485 cards
require a 600-ohm resistor in place of the 120-ohm terminatin g res istor.
Sh ield no t connected at first IED RS-485 IN
Shield connected at first IED
RS-485 OUT
Sh ield no t connected
at IED
RS-485 IN
Shield
connected
at IED
RS-485 OUT
Rules of thumb: RS-485 cable ground should always be connected at the previous IED, never upon arrival at an IED. All RS-485 IEDs must have either two communications cables attached or one communications cable and a terminating resistor.
Shield not
RS-485 IED #31
Shield
120-ohm terminating resistor
+
-
connected
at IED
RS-485 IN
Figure 9. Network illustrating Modbus Rules 4 and 5.
6. A single RS-485 network may have up to 215 commnet IEDs attach ed to it via POWER LEADER Modbus Concentrators. Figure 10 illustrates this rule.
16
Power Management Control System
Chapter 2 – Network Design
Host
RS-485 IEDs
(31 Max)
MC
Modbus
Concentrator
Commnet IEDs
(up to 32 per Modbus Concentrator,
215 tota l per RS-485 network)
Figure 10. Network illustrating Modbus Rule 6.
7. A single RS-485 network may have no more than 4000 feet of cable (total cable length, not distance between IEDs). Figure 11 illustrates this rule.
RS-485 IEDs
Host
100 ft
Total Cable Length < 4000 feet
200 ft 300 ft
(31 M ax)
1500 ft
9. There may be no more than two RS-485 repeaters between any two RS-485 IEDs. Figure 13 illustrates this rule.
Rptr Rptr
Correct - Maximum two repeaters between RS-485 IEDs
Rptr Rptr Rptr
Incorrect - more than 2 repeaters between RS-485 IEDs
Figure 13. Network illustrating Modbus Rule 9.
NOTE ON DUAL-PORT RS-485 IEDS:
Several of th e Mul tilin pow er man agement I EDs offer two RS-485 ports on the same IED. Do not connect both RS-485 ports to a PMCS network. The same data are available from both RS-485 ports and will cause conf licts if the PMCS attempts to access both ports simultaneously.
However, the Modbus Mo nitor’s wiring sche m e is slightly differe nt from the Multilin sch eme. The dual-port version of the POWER LEADER Modbus Monitor MUST be connected to two separate RS-485 networks. S ee Rule 10 fo r d e tails.
300 ft
1500 ft
Figure 11. Network illustrating Modbus Rule 7.
8. RS-485 repeaters may be used to extend the range beyond 4000 feet. A single RS-485 repeater may be used to provide a 4000-foot extension, and each additional repeater in a sequence extends the range by another 4000 feet. Figure 12 illustrates this rule.
Host
100 ft
With 2 Repeaters,
Total Cable Length < 8000 feet
200 ft
500 ft 700 ft
4000 ft
2500 ft
R
R
RS-485
Repeaters
Figure 12. Network illustrating Modbus Rule 8.
10. Modbus Monitors (dual-port version) may not be wired in any configuration other than the four shown in Figure 14 . Although the Monitor’ s RS-485 ports have separate addresses, you may NOT wire the same Modbus n etwork to both por ts. A two-port Modbus Monitor must be wired to two separate Modbus networks .
NOTE: For more information on wiring the POWER LEADER Modbus Monitor, refer to DEH-027, Modbus Monitor User’s Guide.
17
Power Management Control System
Chapter 2 – Network Design
Modbus
Segment A
Modbus
Segment A
Example B
Modbus
Segment B
Monitor
#1
Example D
Modbus
Segment B
Monitor
#1
Monitor
#2
Example A
Modbus
Segment A
Monitor
#1
Example C
Modbus
Segment A
Monitor
#1
Monitor
#2
Figure 14. Valid Modbus Monitor network architectures.
CAUTION: Any other wiring of the Modbus Monitor may result in incorrect operation and errors.
makes this concern irrelevant for examples A, B, and D, since in Example A you could have either a single- or a dual-port Monitor, while in Examples B and D you may only use a dual-port monitor(s).
CAUTION DUAL PORT MONITO R USERS: Do not connect the Monitor’s two RS-485 ports to the same Modbus segment. This will cause communication
errors and possibly damag e the Monitor.
Example A shows a single Modbus Monitor wired to one Modbus segment. Example B shows the same monitor in a dual-port version, wired to two different Modbus segments.
Examples C and D illustrate fully loaded Modbus segments. No more than two Monitors are permitted on any Modbus segment.
Example C illustrates a pair of Monitors connected to a single Modbus segment. In this example, the Monitors may be either single port or dual-port versions, provided both are the same version (see note below). Example D shows the same pair of Monitors wired to a second Modbus segment.
CAUTION: With regard to Example C (two Monitors on a single RS-485 segment), it is not permissible to mix different models of Monitors on a segment. Monitors #1 and #2 must be of the same model, either both sin gle-p ort or both d ual­port.
The nature of the other network architectures
18
Power Management Control System
g
g
)
Chapter 2 – Network Design

2–6 Commnet Wiring Rules – Diagrams

POWER LEADER commnet IE Ds may be integrated into PMCS through the us e of the POWER LEADER M odbus Concentrator, which collects data from commnet IEDs and communicates that data across the RS-485 network. Each Modbus Concentrator supports up to eight commnet segments. Each commnet segment may accommodate up to four commnet IEDs. The following are the basic rules to ensure proper network operation for POWER LEADER commnet IEDs. Note that these rules apply only to individual commnet segments of a POWER LEADER Modbus Concentrator, no t to the RS-485 network.
1. Each Modbus Concentrator supports up to eight commnet segments. Each commnet segment may support up to four commnet IEDs, only one of which may be a waveform-capturing meter. POWER LEADER Repeaters and Junction/Outlet Box es are not counted as commn et IEDs. Figure 15 ill ustrates this rule.
Modbus
Concentrator
4 co mm net IEDs/seg me nt
max
degrades and the danger of errors rises to an unacceptable level. The Repeater regenerates a signal to its origina l stre ngth, a llowin g it to trav el up to another 1000 feet. Thus, each Repeater can add up to 1000 feet of range t o the commnet segment.
For example, a segment containing a single Repeater may have no more than 2000 feet of total cable length. No more than 1000 feet of cable are permitted between the Modbus Concentrator and the first Repeater or between the Repeater and the last IED on the segment. Figure 17 illustrates this rule.
CAUTION: In no case may there be more than 1000 feet of cable between any two commnet IEDs other than Repeaters. At ranges over 1000 feet, commnet signals become degraded and communication errors may result.
Modbus
Concentrator
400 ft
R
200
600
ft
ft
Max length of a commnet segment
with one Repeater < 2000 feet
600
200
ft
ft
Figure 15. Network illustrating commnet Rule 1.
2. A commnet segment may have no more than 1000 feet of cable between the Modbus Concentrator and the final IED on a segme nt. (Re peater s ma y be used to extend this range; see Rule 3.) Figure 16 illustrates this rule.
Modbus
Concentrator
300 ft
200
200
ft
th of a co mm net segment < 1000 feet
Max len
200
ft
ft
Figure 16. Network illustrating commnet Rule 2.
3. The maximum communication range of commnet IEDs (including the Modbus Concentrator’s commnet ports) is 1000 feet, after which its signal
Figure 17. Network illustrating commnet Rule 3.
4. Long-distance cable runs may be built by placing two Repeaters adjacent to one another in the segment. A pair of adjacent Repeaters has a range of up to 6000 feet of cable. Figu re 18 illustrates this rul e .
Modbus
Concentrator
400 ft
R R
6000
1000 ft
RR
6000
ft
Max length of a commnet segment with three Repeaters < 12000 feet
(note: only one other IED may be used o n
a commnet se
600
ft
ft
Max length of a commnet segment
with two Repeaters < 8000 feet
4000
ft
men t w ith three repeaters
600
R
ft
200ft200
1000
ft
ft
Figure 18. Network illustrating commnet Rule 4.
5. The maximum allowable cable length of a single commnet segment is 12,000 feet. This may be
19
Power Management Control System
Chapter 2 – Network Design
achieved with any allowable combination of Repeaters and IEDs.
6. For ease of wiring, the POWER LEADER Junction/Outlet Box may be used to c reate node s of commnet IEDs with a common wiring point to be connected to the Modbus concentrator. The POWER LEADER Junction/Outlet Box allows the interconnection of as many as f our sh ielde d, tw isted ­pair cables to c rea te this common wir ing poin t. T his can be of great help in economizing on wiring and offering greater flexibility in network design. For instance, rather than a daisy-chain of the wiring in a lineup from one meter or tr ip u nit to the n ext, u p to four IEDs may be wired to the POWER LEADER Junction Box, which is then connected to the Modbus Concentrator.
CAUTION: The four-IED-per-segment limit must be observed at all times. Although the POWER LEADER Junction Box has terminals to accept up to 12 commnet lines, do NOT connect more than four commnet IEDs to a single Junction Box or Modbus Concentrator commnet segment.
Examples of the use of a POWER LEADER Junction Box with the Modbus Concentrator are provided in Figure 19 and Figure 20. Junction Boxes are not counted as IEDs for purposes of the four IED per commnet segment limit. Figure 19 is an example of a Junction Box used to create a node connecting four commnet IEDs to a Modbus Concentrator. Figure 20 is an example of a Junction Box with Repeaters, observing the four IED per segment limit (the two Repeaters and the Junction Box do not count as IEDs).
commnet
IED
to
Modbus
Concentrator
comm n e t
IED
Junction
Box
comm n e t
IED
comm n e t
IED
Figure 19. Network illustrating commnet Rule 6.
commnet
to
Modbus
Concentrator
comm n e t
IED
IED
Junction
Box
commnet
IED
Long-range
comm net segment
POWER LEADER Repeater
POWER LEADER
Repeater
comm n et
IED
Figure 20. Network illustrating commnet Rule 6.
20
Power Management Control System
Chapter 2 – Network Design

2–7 Performance Recommendations

Although a PMCS network will function as long as all the rules in the previous section are followed, you can enhance performance by considering the following recommendations for Modbus, commnet.

The Ideal Network

Theoretically, a single Modbus IED or 40 commnet IEDs distributed across five Modbus Concentrators (one IED per commnet segment) yields maximum performance.
Naturally, in the r eal world few ne tworks will fall into th is precise configuration. To extract maximum performance from the PMCS, follow the performance recommendat ions below.

Modbus performance recommendations

Use multiple RS-485 networks if possible, depending
1. on the RS-485 connection at the host. If using an eight-port RS-485 card or an Ethernet Gateway (four ports) for connection to the network, you can improve performance by using the full number of ports available, rather than burdening a single RS-485 port. Distributing the IEDs across all available RS-485 ports permits the communications load to be distributed rather than asking a single network to carry the full load.
Divide the IED loads evenly when distributing IEDs
2. across multiple RS-485 networks.
Pay careful attention to Modbus Rule 2, regarding the
3. communication speeds of IEDs on a given network. Although a network w ill function with mixed IE Ds, its communication speed will be dragged down to the lowest common denominator. Thus, a single 2400­baud IED forces the e ntir e ne twor k to commun icate a t 2400 baud, regardless of the presence of any 19.2­kbaud IEDs.

Commnet performance recommendations

Modbus is preferred over commnet where either
1. protocol is available. This is the case for the POWER LEADER Electronic Power Meter and the POWER LEADER MDP Overcurrent Relay. Each of these IEDs offers a Modbus communications option.
Minimize the number of commnet IEDs per segment.
2. The Modbus Concentrator is a polling IED, meaning that it queries each commnet segment continuously and in order asking for information. It then stores the
information until it is asked b y the PMCS to transmit its data to the host. If the n umber of c ommnet IEDs is unevenly distributed, the Concentrator takes longer than necessary to poll each segment.
3. Keep data-intensity in mind when connecting more than eight commnet IEDs to a single Modbus Concentrator. If it is necessary to connect more than eight commnet IEDs to a single Modbus Concentrator, one or more segments will be supporting multiple IEDs. Keep the following list in mind when selecting which IEDs to double up on the same commnet segment. The best choices for doubling up are listed first.
Spectra MicroVersaTrip trip unit
1.
2. Enhanced MicroVersaTrip-C and -D trip units
3. POWER LEADER MDP Overcu rre nt Relay
4. Spectra Electronic Control Module
5. POWER LEADER Electronic Power Meter
6. POWER LEADER Meter
IEDs at the top of the list are less data-intensive and easier for the Concentr ator to p oll. IE Ds at th e bottom of the list are very data-intensive and, if possible, should be given their own commnet segment. In other words, if you must put multiple IEDs on a segment, it is preferable to put low-demand IEDs together on a segment and try to keep high-demand IEDs on their own segments. Try to distribute the high-demand IEDs across the available segments, keeping the number of high-demand IEDs per segment evenly distributed.

2–8 Addressing the IEDs

Each IED attached to a PM CS network must have a u n iq u e address. Prior to installing any wiring, you should plan the addresses for the IEDs to avoid any conflicts. Keep in mind these important points when assigning network addresses.
• Keep a table of IED names and addresses to avoid conflicts and to help with host configuration. Table 5 summarizes Modbus addressing considerations, based on the following rules.
- Modbus Concentrator addresses must be in the range of 1 to 32.
- Modbus-native IEDs other than the Concentrator may occupy any address from 1 to 247.
- Commnet IEDs must have Modbus-equivalent addresses in the range of 33 to 247.
- The host PC does not require an address due to the master-slave organization of the PMCS.
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Power Management Control System
Chapter 2 – Network Design
NOTE: Per the EIA485 standard, each RS-485 network supports up to 32 “drops” or electrical drains on the network. However, the Ethernet Gateway or RS-485 interface card counts as one drop. Thus, only 31 other IE Ds may be attached to each RS-485 network, even though 32 Modbus addresses are available for use. Also, unlike commnet’s POWER LEADER Repeaters, RS-485 repeaters are counted as IEDs because although they have no Modbus address, they do act as a drop on the network.
Modbus Address
0 Broadcast (not available to user)
1 – 32 Modbus Concentrators must have addresses
33 – 247 Modbus native IEDs may have addresses in
Table 5. Modbus address range appropriate usage.
• Commnet IEDs are preprogrammed with a factory-set address. You must change this address immediately upon installation of the I ED. Refer to the IE D’s user manual for instructions on assi g ni ng an address.
• Because the commnet network accepts a different range of addresses than the Modbus network, commnet addresses must be mapped to corresponding Modbus addresses. The formula for
Appropriate Usage/Supported IEDs
in this range
Other Modbus native IEDs may also have addresses in this range
this range
Commnet IEDs must have addresses in this range
this mapping is: desired Mod b u s a d dress + 267 = commnet address to set at IED. For example, to set a commnet IED to Modbus address 33, the commnet address set at the IED must be 300. Table 6 illustrates address mapping.
For Modbus Address: Set commnet IED Address to:
33 300 34 301 35 302
... ...
246 513 247 514
Table 6. Modbus-to-commnet address mapping.
- You may wan t to block commnet address assignmen ts by lineup and/or Modbus Concentrator segment. For example, start with 40 for the first l ineup attache d to one Modbus Concentrator, 50 for the second lineup attached, and so on. Addresses must be in the range 33 to 247. The example presented in Figure 18 demonstrates this.
- Increment the individual IEDs in each lineup by one. For example, if the first IED in a lineup is Modbus address 101, the second IED should be 102, the third IED should be 103, etc.
• Addresses may be entered or changed at any time that control po we r is present.
Figure 21 illustrates a sample network with IED addresses; Table 7 provides details of the IEDs shown in Figure 21.
22
Power Management Control System
Chapter 2 – Network Design
Figure 21. Sample network with IED addresses.
23
Power Management Control System
Chapter 2 – Network Design
Equipment
Lineup 1
POWER/VAC Medium-Voltage Switchgear
Lineup 2
8000-Line Motor Control Center
Lineup 3
AKD-8 Low-Voltage Switchgear
Lineup 4
Medium-Voltage Motor Control Center
Lineup 5
Substation
Attached IEDs
Modbus Concentrator 1
Segment 1
POWER LEADER Electronic Power Meter MDP Overcurrent Relay with commnet MDP Overcurrent Relay with commnet MDP Overcurrent Relay with commnet
Segment 2
POWER LEADER Electronic Power Meter POWER LEADER Electronic Power Meter
Segment 3
POWER LEADER Electronic Power Meter POWER LEADER Electronic Power Meter
Segment 4
MDP Overcurrent Relay with commnet
MDP Overcurrent Relay with commnet EPM 7700 Electronic Power Meter Multilin 269 Plus Motor Relay Modbus Concentrator 2
Segment 1 - Spectra Electronic Control Module
Segment 2 - Spectra Electronic Control Module
Segment 3 - Spectra Electronic Control Module
Segment 4 - Spectra Electronic Control Module
EPM 7700 Electronic Power Meter using IP address =
3.46.9.102
Modbus Concentrator 3
Segment 1 - POWER LEADER Meter
Segment 2 - Enhanced MicroVersaTrip trip unit
Segment 3 - POWER LEADER Meter
Segment 4 - Enhanced MicroVersaTrip trip unit
GE Fanuc Programmable Logic Controller 90/30 Multilin 565 Feeder Management Relay EPM 5300P EPM 5200P EPM 9650Q EPM 7300 EPM 7330 EPM 7330
Modbus
Address
001 035
036 037 038
040 041
045 046
050 051
052 060 002
065 070 085 090
n/a
003 155 160 165 170 175 180 185
004 005 200 205 210 215 220 225
Commnet
Address
302 303 304 305
307 308
312 313
317 318
— —
— 332 337 352 357
n/a
— 422 427 432 437 442 447 452
Table 7. IED-addressing scheme for Figure 21.
24
Power Management Control System
Chapter 2 – Network Design

2–9 Multiple RS-485 Networks – Addressing

PMCS supports up to 256 inde pe nd e nt Modbus networks. Regardless of how many RS-485 networks are connected,
the addressing concepts regarding multiple RS-485 networks remain the same. Each RS-485 network is addressed independently of the others. Thus, Network 1 may have an IED with Modbus address 20, and Network 2 may have an IE D with Modbus ad d r e s s 20 without c on f l ic t. The PMCS will be aware that they are different IEDs, much as the postal system delivering mail realizes that 17 Mulberry Lane in Town A is a different address than 17 Mulberry Lane in Town B.

2–10 System Expansion

Whenever new IEDs are added to the network, be sure to observe these points:
• Follow the proper installation procedures.
• Ensure that the system configuration rules have been followed.
• All new IEDs are shipped with the same default address. To avoid conflicts, change the address of each new IED immediately upon installation to an unoccupied address in the PMCS networks.

2–11 Case Studies

Five case studies are provided as examples of how to design a network based on PMCS. In each case, a fictitious company called GHO Corp. is installing a power management system based on PMCS.
In Case One, GHO Corp. has only a few Modbus RTU­based IEDs that it would like to network to the PMCS software for remote control and viewing of power consumption and alarms.
In Case Two, GHO Corp. wishes to expand the Modbus network it developed in Case One by adding some commnet IEDs to the network.
In Case Three, GHO Corp. already has an existing network based on Ethernet and would now like to integrate a power management system with this network. GHO Corp. still has only a few Modbus RTU-based IEDs that it would like to network to the PMCS for remote control and viewing of power consumption and alarms. Now, however, it wants the host to be based on Ethernet rather than Modbus, which requires the use of an Ethernet Gateway.
In Case Four, GHO Corp. wishes to install a PMCS power management system using both Modbus- and commnet­based IEDs, with the host based on Ethernet.
Case Five demonstrates the use of dual-port RS-485 IEDs in a Modbus network, showing the differences between the Multilin dual-port IEDs and the POWER LEADER Modbus Monitor, which also provides two RS-485 po rts.

Case Study One

GHO Corp. has assigned its plant engineer, Bill, the task of designing and installing a simple power management system. GHO Corp. wishes to use PMCS to monitor and control several Modbu s power management IEDs.
Bill’s first task is an easy one. He must choose a platform on which the PMCS host will r e s ide . Us ing the flowchart in Section 1-1, he makes his decision. There is no existing Ethernet network in his facility, nor are there any plans for one. Bill chooses Modbus as his basic platform for the PMCS.
Next, Bill makes a list of the IEDs that GHO Corp. wants to include on their PMCS network:
• One PLC 90/30 Programmable Logic Controller for process control
• Three EPM 3720 Meters for monitoring power
• One Multilin 269+ Mot o r Re lay for motor protection
• One Multilin 565 Feeder Management Relay for feeder protection
He checks the list of communications protocols in Table 1 and notes that all of the IEDs communicate on Modbus; because no commnet IEDs are being used, no Modbus Concentrators are needed. The Modbus IEDs communicate at different baud rates, though, and Bill makes a note that they should be placed on separate RS­485 networks for improved performance.
Bill now turns to his floor layout to see just where the wiring could be run and how many feet of cable will be needed. He maps where his IEDs must be located and where the host PC will sit. He measures the cable runs required to connect the IEDs to the host PC, keeping in mind that the wirin g rules require him to daisy-chain the IEDs on each RS-485 network one after another. His floor layout is shown in Figure 22.
25
Power Management Control System
Chapter 2 – Network Design
Terminating
Resistors
Lathe Ar ea
Bill's Office
Multilin 565 Feeder Management Relay
Ma in pow er feed
550'
Mu ltil in 269 + Motor Relay
300'
Assembly Line Area
EPM 3720 Ele c tr onic P owe r Meter
EPM 3720 Ele c tr onic P ower M eter
200'
GHO Corp Machine Shop -
PLC 90/30 Programmable Logic Controller
network wiring diagram
350'
EPM 3720 Ele c tr onic P ower M eter
Machining Area
350'
Milling Area
550'
Figure 22. Floor layout for Case One.
Bill’s calculates his total cable length at 2300 feet, well short of the 4000-foot limit.
Next, Bill checks Table 2 for the Modbus wiring rules. Proper termination is required at each end of the network,
and is provided at the RS-485 card by attaching jumpers to the correct pins (see RS-485 card user manual). The appropriate terminating resistors must be used at the opposite end of each RS-485 network, per Section 2–4, rule
3. His cable length is well under the 4000-foot limit, so no
repeaters will be needed. Because he has only six IEDs to connect, only one RS-485
network is required, and thus an RS-232/RS-485 converter would do the job. However, he considers the performance recommendations given in Section 2-6 and, remembering his earlier note about the different baud rates of his Modbus IEDs, he decides to distribute the IEDs across four ports of an RS-485 network card, so that he can place IEDs with matching baud rates on the same RS-485 netwo rk.
The system redesigned for optimum performance is shown in Figure 23.
RS485 networks terminated at ho s t P C
d u a b
0 0 6 9
­1 k
r o w
t e N
Bill's Office
100'
Multilin 565 Feeder Manage ment Rel ay at m ain powe r feed
d u a b
0 0 4 2
­2 k
r o w
t e
600'
N
Multilin 269+ Motor Relay
Terminating Resistors
Network 4 - 19.2 kbaud
Network 3 - 19.2 kbau d
Assembly Line Area
GHO Corp Machine Shop ­network wiring diagram
Lathe Ar ea
EPM 3720 Ele c tr onic P ower M eter
600'
EPM 3720 Ele c tr onic P ower M eter
Machining Area
EPM 3720 Ele ctronic Power Me ter
PLC 90/30 Programmable Logic Contro ller
350'
Milling Area
550'
Figure 23. Redesigned layout for Case One.
Confident that his new design will provide maximum performance, and with his wiring requirements and limits met, Bill moves on to select Modbus addresses for the IEDs. He checks Section 2-7 and sees that he can assign his IEDs any Modbus address between 1 and 247. He selects addresses and records them for future reference. The address chart is shown in Table 8.
IED Type Physical Location Modbus Add re ss
PLC 90/30 Assembly line 01 EPM 3720 Milling 02 EPM 3720 Lathe area 03 EPM 3720 Machining 04 Multilin 269+ Assembly line 05 Multilin 565 Power intake area 06
Table 8. IED Addresses for Case One.
Chapter 3 provides Bill with physical wiring requirements and rules. He finds that he’ll have to use Belden 3074F cable, readily available. He also locates the correct terminating resistors at both ends of each RS - 485 ne twork.
He installs the IEDs according to the instructions in the user manual for each IED. He then makes connections to the RS-485 communications cable in daisy-chain fashion, one IED to the next, terminated at each end of each RS­485 network, double-checking his wiring against the example provided in Section 2–4.
He must also bear in mind proper shield-grounding considerations – each RS-485 IED grounded at only one
26
Power Management Control System
Chapter 2 – Network Design
point and no two IEDs’ grounds connected (Rule 4, Section 2-4).
Bill assigns a Modbus address to each IED. He then sets communication speeds and functional and protective parameters according to the instructions in each user manual.
Bill installs the PMCS software at the host PC and configures IED addresses at the host to match the addresses assigned to each on the network.
When all connections have been made and the IEDs and software are appropriately configured, Bill applies power to the system and runs tests to assure that everything is functioning properly.
If any difficulties are encountered, Bill refers to the trouble-shooting guide in Chapter 4.

Case Two

Case Two begins where Case One left off. The Modbus network is in place and GHO Corp. has been so pleased with their new P MCS system tha t they now wis h to tie in a second building (Facility Two) and add several additional power management IEDs. However, the IEDs they wish to add are all commnet IEDs.
easier and more cost effective to run a single long RS-485 segment with a pair of RS-485 repeaters than to extend six commnet segments. An added benefit: each repeater uses optical isolation be tween its incoming an d outgoing lines, eliminating harmful ground loops that can result when the ground potential between two structures is different. For even greater electrical isolation Bill could have used an optical fiber link between the two remote locations.
Bill turns to his floor layout, to see just where the wiring could be run and how much distance it must cover. He knows where his host PC is located and realizes that he will have to interrupt the Modbus network at one or more locations to insert Modbus Concentrators to support his commnet IEDs. He maps where his IEDs must be located and, based on this information, where the Concentrators will be mounted. Next he plans the commnet segments and measures the cable runs required for each segment to connect the IEDs to the Modbus Concentrator, keeping in mind that the commnet rules require him to daisy-chain the IEDs one after another (unless he uses a Junction/Outlet box). His floor lay out is shown in Figure
24.
The host platform is based on Modbus, with a multi-port RS-485 interface card providing the connection to the networks. Knowing the host platform and its currently attached IEDs, Bill makes a list of the IEDs that GHO Corp. want to add to their PMCS network. His list of additional IEDs is:
• Six Enhanced MicroVersaTrip trip units for equipment protection
• Three POWER LEADER Meters fo r wave form capture
• One POWER LEADER EPM
• One POWER LEADER MDP Overcu rre nt Relay
• One Spectra Electronic Control Module
Commnet IEDs require Modbus Concentrators to be recognized by the PMCS. Bill has nine commnet IEDs to connect, so he will need only one Modbus Concentrator (each Concentrator supports up to 32 commnet IEDs). However, with some of the commnet IEDs located in Facility Two, well beyond the 1000-foot segment limit, Bill realizes that he must either locate the Modbus Concentrator in Facility 1 and run several very long commnet segments using POWER LEADER Repeaters to span the long runs or place a Modbus Concentrator in Facility Two and extend his RS-485 network over to Facility Two with RS-485 repeaters. Bill decides that it will be
27
Power Management Control System
Chapter 2 – Network Design
RS485 networks terminated at ho st PC
Bill's Office
d u a b
100'
0 0 6 9
­1 k
r o w
t e N
Facility Two
d u a b
0 0 4 2
­2 k
r o w
t e N
Network 4 - 19.2 kbaud
Network 3 - 19.2 kbaud
Multilin 565 Feeder Manage ment Rel ay at m ain powe r feed
600'
Multilin 269
Terminating Resistor
Assembly Line Area
EMVTPLEPM
EMVTEM VT
300'
RS485 repeater
Long-range RS485 cable run 3500 feet
RS485 repeater
Modbus
Concentrator
Segment 3
POWER LEADER
Meter
GHO Corp Machine Shop ­network wiring diagram
EPM 3720
Figure 24. Floor layout for Case Two.
He must also bear in mind proper shield grounding considerations – each RS-485 IED grounded at only one point and no two IED’s grounds connected (Rule 4, Section 2-4).
Bill checks Table 4 for the commnet wiring rules and finds that he must keep his POWER LEADER Meters on separate commnet networks, limit his commnet IEDs to four per segment, and keep each segment under 1000 feet (unless he uses repeaters). The commnet segments he has planned satisfy all these rules.
Because his cabling limits are met, Bill selects Modbus­equivalent addresses for the IEDs and adds them to his address chart for future reference. His updated address chart is shown in Table 9.
Lathe Ar ea
600'
EPM 3720
Machining Area
EPM 3720
PLC 90/30 Programmable Logic Controller
Terminating Resistor
Segment 5Commnet Segment 1
EMVT
EMVT POWER
Segment 4Segment 2
MDP POWER LEADER
EMVT
Meter
ECM
350'
Milling Area
550'
LEADER
Meter
IED Type Physical Location Modbus Address
PLC 90/30 Assembly line 01 EPM 3720 Milling 02 EPM 3720 Lathe area 03 EPM 3720 Machining 04 Multilin 269+ Assembly line 05 Multilin 565 Power Intake area 06 Modbus
Concentrator Enhanced
MicroVersaTrip Enhanced
MicroVersaTrip Enhanced
MicroVersaTrip Enhanced
MicroVersaTrip Enhanced
MicroVersaTrip Enhanced
MicroVersaTrip POWER
LEADER Meter POWER
LEADER Meter POWER
LEADER Meter POWER
LEADER EPM MDP
Overcurrent Relay
Spectra ECM Facility 2, Segment 3 44
Bill next checks Chapter 3 for physical wiring requirements and rules. He knows he needs Belden 3074F cable for the new RS-485 wiring to extend RS-485 Network 3 to the RS-485 repeater for the jump to Facility Two and to make the connection to th e Modbu s Con centr ator f rom the RS-485 repeater in Facility Two. He moves the terminating resistor from the end of RS-485 Network 3 out to the new end at the Modbus Concentrator in Facility Two.
Facility 2, north wall 10
Facility 2, Segment 1 33
Facility 2, Segment 2 34
Facility 2, Segment 2 35
Facility 2, Segment 3 36
Facility 2, Segment 5 37
Facility 2, Segment 5 38
Facility 2, Segment 3 39
Facility 2, Segment 4 40
Facility 2, Segment 5 41
Facility 2, Segment 1 42
Facility 2, Segment 4 43
Table 9. IED Addresses for Case Two.
28
Power Management Control System
Chapter 2 – Network Design
Commnet wiring requires Belden 8719 cable. Bill installs the IEDs according to the instructions in each user manual. He wires each commnet segment in daisy-chain fashion, one IED to the next, being sure to ground the shield at the Modbus Concentrator only.
Bill then sets local addresses on the IEDs in accordance with the addressing rules in Section 2–6. He sets communication speeds and parameters according to the instructions in each user manual.
Bill installs the PMCS software at the host PC and configures the IED addresses.
When all connections have been made and the IEDs and software are appropriately configured, Bill applies power to the system and runs tests to assure that everything is functioning properly.
If any difficulties are encountered, Bill refers to the trouble-shooting guide in Chapter 4.

Case Three

In Case Three, GHO Corp. has an existing Ethernet network installed and would now like to add power management capabilities with PMCS. Once again, plant engineer Bill has been given the task of designing and installing this system.
As before, Bill ’s first tas k is to choose a platf orm on w hich the PMCS host will r eside. Using the flow chart in Section 1-1, he decides that the PMCS will reside on Ethernet, requiring one or more Ethernet Gateways to communicate with the RS-485 net works.
Next, Bill makes a list of the IEDs that GHO Corp. needs to support on their PMCS network. The IED list is the same as in Case One:
• One PLC 90/30 Programmable Logic Controller for process control
• One EPM 3720 Meter for monitoring power
• One Multilin SR745 Transformer Management Relay
• One Multilin SR469 Mot o r Management Relay
• One Multilin 269+ Mot o r Re lay for motor protection
• One Multilin 565 Feeder Management Relay for feeder protection
The list of communication protocols in Tab le 1 s hows th at all the IEDs communicate on Modbus; because no commnet IEDs are being used, no Modbus Concentrators are needed. However, because the PMCS will be operating on Ethernet, he will need to use an Ethernet Gateway to relay communication s between the host and the Modbus networks. Table 1 also indicates that the Modbus IEDs
have different communication speeds. For performance reasons, Bill decides to break the IEDs off to independent networks rather than connect all of them to the same R S­485 network. The Ethernet Gateway offers four RS-485 ports, so using more than one port poses no additional cost burdens or config u ration concerns.
Bill turns to his floor layout, to see just where the wiring could be run and how much distance it must cover. He maps where his IEDs must be located and where the Ethernet Gateway will sit. He then measures the cable runs required to connect the IEDs to the Ethernet Gateway, keeping in mind that the RS-485 rules require him to daisy-chain the IEDs one after anoth er. His floor layout is shown in Figure 25.
RS485 networks terminated
Ethernet
at Ethernet Gateway
Bill's Office
Network 1 -
9600 baud
Multilin 565 Feeder Mana gement Relay
d u
a b
0
0 4 2
­2 k
r o w
t e N
600'
Multilin 269+ Motor Relay
Terminating Resistors
150'
Network 4 - 19.2 kbaud
Ethernet
Gateway
Network 3 - 19.2 kbaud
Assembly Line Area
150'
Multilin SR745 Transformer Management Relay
600'
EPM 3720 Electronic Power Meter
PLC 90/30 Programm able Logic Controller
GHO Corp Machine Shop ­network wiring diagram
Lathe Area
350'
Milling A rea
Multilin S R 469 Motor Management Relay
Machining Area
550'
Figure 25. Floor layout for Case Three.
Next, Bill checks Table 2 for the Modbus wiring rules and Table 3 for the Ethernet wiring rules.
He notes that he must properly terminate the RS-485 network at each en d and that he must keep his total RS­485 cable length under 4000 feet, unless he invests in RS­485 repeaters or puts the IEDs on separate RS-485 networks, which may run in different directions and effectively increase his range.
His cabling limits are satisfied, so Bill selects Modbus addresses for the IEDs, and records them for future reference. His address chart is shown in Table 10.
29
Power Management Control System
Chapter 2 – Network Design

Case Four

RS-485 Port,
IED Type Physical Location
Multilin 565 Power Intake Area 1, 01 Multilin 269+ Assembly Line 2, 01 PLC 90/30 Assembly Line 3, 01 EPM 3720 Machining 3, 02 Multilin SR745 Lathe Area 4, 01 Multilin SR469 Milling 4, 02
Table 10. IED Addresses for Case Three.
Bill next checks Chapter 3 for physical wiring requirements and rules. He finds that he’ll have to use Belden 3074F cable for the RS-485 wiring. He also locates the correct terminating resistors at each end of the RS-485 network.
He installs the IED s according to the instr uctions in each user manual. He makes communication connections to the RS-485 communication cable in daisy-chain fashion, one IED to the n ext, with ter minating r esistor s at the f inal IED and the host (Ethernet Gateway). While wiring, he follows the RS-485 cable shield wiring rules explained in Section 2–4 (rule 4).
Bill then assigns local Modbus addresses to the IEDs and sets communication speeds and parameters according to the instructions in each user manual.
He installs the PMCS software at the host PC and configures the IED addresses to match the addresses set at the IEDs.
When all connections have been made and the IEDs and software are appropriately configured, Bill applies power to the system and runs tests to assure that everything is functioning properly.
If any diffic ultie s ar e e ncou nte red , he re fer s to th e trou ble ­shooting guide in Chapter 4.
Modbus Address
In Case Four, GHO Corp. wishes to create a power management system that will interconnect with their existing corporate Ethernet. They would like the capabilities of both Modbus and commnet IEDs and plan to integrate three separate fac ilities using r epeaters. G HO Corp. plant engineer Bill has been given the task of designing and installing thi s syst em .
As in the previous cases, Bill’s first task is to choose a platform on which the PMCS host will reside. GHO Corp. requires Ether net integration, so the flowc hart in Section 1-1 determines that the PMCS will reside on Ethernet, requiring an Ethernet Gateway.
Next, Bill makes a list of the IEDs that GHO Corp. wishes to support on their PMCS network. His IED list is:
• One PLC 90/30 Programmable Logic Controller for process control
• Two EPM 3720 Meters and one EPM 7700 for monitoring power
• One Multilin 269+ Mot o r Re lay for motor protection
• One Multilin 565 Feeder Management Relay for feeder protection
• Six Enhanced MicroVersaTrip trip units
• Three POWER LEADER Meters (with waveform capture)
• One POWER LEADER EPM
• One POWER LEADER MDP Overcu rre nt Relay
• One Spectra Electronic Control Module
Bill knows that he will need an Ethernet Gateway to connect his Modbu s network(s) to E thernet and both R S­485 and POWER LEADER Repeaters to reach the remote locations in Facility Two and Facility Three. He checks his IED list against the list of communication protocols in Table 1 and notes that some of the IEDs communicate on Modbus and some on commnet, so he will also need at least one Modbus Concentrator to support communications with the commnet IEDs. The Modbus IEDs do not all communicate at the same speed, so more than one RS-485 network is required.
Next, Bill checks Tables 2 through 4 for the Modbus, Ethernet and commnet wiring rules.
The EPM 7700, being a native Ethernet device, can be connected directly to the Ethernet hub Bill intends to install near his office. He’ll connect the hub to the corporate LAN, to his PC, to the 7700, and finally to the Ethernet Gateway. Bill, realizing the LAN is shared by the entire building, installs an Ethernet data line surge
30
Power Management Control System
Chapter 2 – Network Design
protector at the hub on the incoming line from the EPM 7700 IED to shield the rest of the network from potentially damaging transients.
Because he has only six Modbus IEDs (five IEDs and the Modbus Concentrator) and 12 commnet IED s to connect, he requires only one RS-485 network (each RS-485 network accommodates up to 31 Mod bus IEDs and up to 215 commnet IEDs). However, because his Modbus IEDs communicate at several different baud rates, Bill decides to assign them to different RS-485 networks to achieve greater system performance.
He also notes that each RS-485 network must be properly terminated at each end. He must keep the RS-485 cable length of each RS-485 network under 4000 feet, unless he uses RS-485 repeaters, as on Network 3, to span the 3,500 feet to Facility 2.
The commnet rules are also easy to comply with. Each of the commnet segments must be kept under 1000 feet, unless repeaters are used to extend the range of the segments, as is required to reach the commnet IEDs in Facility 3. Each commnet segment is limited to four commnet IEDs, and no segment may have more than one waveform capture meter (POWER LEADER Meter). Bill makes sure that his POWER LEADER Meters are limited to one per segment.
Bill now turns to his floor layout, to see just where the wiring could be run and how much distance it must cover. He maps where his IEDs must be located and where the host PC will sit. He then measures the cable runs required to connect the IE Ds to the host PC, keep ing in mind that the RS-485 rules require him to daisy-chain the Modbus IEDs one after another from the Ethernet Gateway and the commnet IEDs (four per segment) from the Modbus Concentrator. His floor layout is shown in Figure 26.
The RS-485 cabling is less than 4000 feet for each of the RS-485 networks, except for Network 3, where RS-485 repeaters are used to bridge the 3,500 feet to Facility Two. Each of the commnet segments requires less than 1000 feet of cable, except for segment three, where POWER LEADER Repeaters are used to span the 5000 feet to Facility Three. The wiring rules are satisfied.
Bill selects Modbus addresses for the Modbus IEDs and Modbus equivalent addresses for the commnet IEDs, using the worksheets in the back of the Modbus Concentrator User Guide (GEH-6491), and records them for future reference. Bill’s address chart, found in Table 11, follows the floor layout.
Ethernet connection to corporate LAN
Bill's Office
Multilin 565 Feeder Mana gement Relay at main power feed
Facility Three
100'
POWER LEADER
Meter
Ethernet
Network 1 ­9600 baud
Multilin 269
Terminating Resistor
Ethernet
Hub
Ethernet Gateway
600'
EMVT
Network 2 ­2400 baud
Assemb ly
Ethernet connection to EPM 7700 is surge-protected
Ethernet
RS - 485 networks term inated
at Ethernet Gateway
Network 3 - 19.2 kb aud
Line
Area
ECM
600'
PLC 90/30 Programm able Logic Controller
RS485 repeater
POWER LEADER
Repeater
EPM 3720
Lathe Ar ea
650'
EPM 3720
Machining Area
Figure 26. Floor layout for Case Four.
EPM 7700
Millin g A rea
550'
Long-range
RS485 cable run
3500 feet
Long-range commnet cable run
5000 feet
Facility Two
PLEPM
EMVT
Segment 2
EMVT
EMVT
RS485 repeater
Modbus
Concentrator
Segment 3
POWER LEADER Repeater
Terminating Resistor
Segment 5Commnet Segment 1
EMVT EMVT
Segment 4
MDP POWER LEADER
Meter
POWER
LEADER
Meter
31
Power Management Control System
Chapter 2 – Network Design
IED Type Physical Location RS-485 Port, Modbus
Multilin 565 Power intake area Port 1, IED 01 Multilin 269+ Assembly line Port 2, IED 01 EPM 7700 Lathe area N/A - native Ethernet IED PLC 90/30 Assembly line Port 3, IED 02 Modbus Concentrator Facility 2, north wall Port 3, IED 03 EPM 3720 Machining Port 4, IED 01 EPM 3720 Milling Port 4, IED 02 Enhanced MicroVersaTrip trip unit Facility 2, Segment 1 Port 3, IED 33 Enhanced MicroVersaTrip trip unit Facility 2, Segment 2 Port 3, IED 40 Enhanced MicroVersaTrip trip unit Facility 3, Segment 2 Port 3, IED 41 Enhanced MicroVersaTrip trip unit Facility 2, Segment 3 Port 3, IED 50 Enhanced MicroVersaTrip trip unit Facility 2, Segment 5 Port 3, IED 70 Enhanced MicroVersaTrip trip unit Facility 2, Segment 5 Port 3, IED 71 POWER LEADER Meter Facility 3, Segment 3 Port 3, IED 51 POWER LEADER Meter Facility 2, Segment 5 Port 3, IED 72 POWER LEADER Meter Facility 2, Segment 4 Port 3, IED 60 POWER LEADER EPM Facility 2, Segment 1 Port 3, IED 34 POWER LEADER MDP Overcurrent Relay Facility 2, Segment 4 Port 3, IED 61 Spectra ECM Facility 3, Segment 3 Port 3, IED 52
(or equivalent) Address
Table 11. IED Addresses for Case Four.
Chapter 3 provides physical wiring requirements and rules. For commnet wiring, he’ll use Belden M8719 cable. For RS-485 wiring, he’ll use Belden 3074F cable and the correct terminating resistors for both ends of the RS-485 networks.
Bill installs the IEDs at the equipment according to the instructions in each user manual and runs the RS-485 cable for each RS-485 network from the Ethernet Gateway to each Modbus IED in daisy-chain fashion, one IED to the next, and terminated at each end.
Bill runs the commnet cable from the Modbus Concentrator for each commnet segment, grounded only at the Modbus Concentrator.
He assigns local Modbus addresses to the Modbus IEDs and sets communication speeds and parameters according to the instructions in each user manual.
Next, Bill sets the local address at each commnet IED according to what he wan ts th e M od b u s -e q u iv a l ent address of each IED to be. He configures the Modbus Concentrator, either manually or with the autoconfigure
option, following the instructions in the Concentrator User Manual. During configuration, the Concentrator probes each of its commnet segments for IEDs, records their commnet addresses, and assigns a Modbus-equivalent address so that communication from the PMCS will be directed to the correct IED.
Bill configures the Ethernet Gateway, assigning a unique IP network address after he checks with the LAN administrator to determine which IP addresses are available. He then sets the serial port communication parameters for each Gateway port after referring to document GEH-6505, Ethernet Gateway User’s Guide, for information on configuring the Gateway serial ports.
Bill assigns a unique IP address to the EPM 7700 meter’s Xpress Card based on information in the EPM 7700 user documentation and the addresses he received from the LAN administrator.
He installs the PMCS software at the host PC and configures the IED addresses in the DDE server. Next, Bill modifies the 7700 network configuration file for the EPM
32
Power Management Control System
Chapter 2 – Network Design
7700, according to the GE 7700 Gateway User’s Guide (DEH-
40035). When all connections have been made and the IEDs and
software are appropriately configured, Bill applies power to the system and runs tests to assure that everything is functioning properly. If any difficulties are encountered, he refers to the trouble-shooting guide in Chapter 4.

Case Five

In this case study, the circumstances are similar to those in Case One, with the addition of several RS-485 dual-port IEDs. The PMCS host resides on Modbus, connected to several RS-485 Modbus segments.
The IED list is:
• One EPM 7300 Electronic Po we r Me ter
• One Multilin SR745 Transformer Management Relay
• One Multilin SR760 Feeder Manag ement Relay
• One Multilin 269+ Motor Relay
• One Multilin 565 Feeder Managem e nt Relay
• Two dual-port RS-485 Modbus Monitors to serve as remote-viewing stations for the IEDs on segments 3 and 4
• One Modbus Concentrator to support the commnet IEDs below
• One POWER LEADER Elect ronic Power Meter
• One Spectra Electronic Control Module
• One Enhanced MicroVersaTrip-C trip unit
He checks the list of communication pr otocols in Table 1 and notes that most of his IEDs communicate on Modbus, but because he wants to use several commnet IEDs in the Machining area, he’ll need a Modbus Concentrator. As well, the Modbus IEDs communicate at different baud rates, and Bill makes a note that they should be pla ced on separate RS-485 networks for improved performance. He decides to use four RS-485 networks supported by the recommended communications card at the host PC.
Bill now turns to his floor layout to see just where the wiring could be run and how many feet of cable will be needed. He maps where his IEDs must be located and where the host PC will sit. Next he measures the cable runs required to connect the IEDs to the host PC, keeping in mind that the wirin g rules require him to daisy-chain the IEDs on each RS-485 network one after another.
Bill calculates the cable length of each RS-485 network and finds that none are over the 4000-foot limit, so he won’t need to use any RS-485 repeaters. The commnet segments
are also within the wir ing limits, so no POWER LEADER Repeaters are required.
The factory floor is very large though, and B ill wants to be able to view IED data at several locations to save walking all the way back to his of fice every time he wants to check an IED. To serve this purpose, he’s purchased a pair of dual­port Modbus Monitors, which he will install in the Milling and the Machining areas, respectively. He checks the Modbus Monitor wiring rules and sees that he’ll be able to connect RS-485 Network 3 to the RS-485 Port A of each Monitor and RS-485 Network 4 to the RS-485 Port B of each Monitor. This will allow him to view data from the IEDs in these areas at either station as well as back in his office at the host PC.
Proper termination is required at each end of the network and is provided at the RS-485 card by placing jumpers between the correct pins (see RS-485 card user manual). The appropriate terminating resistors must be used at the opposite end of each RS-485 network, per Section 2–4, rule
4. The network architecture diagram Bill creates is shown in
Figure 27.
RS-485 networks terminated at host PC
d u a b
0 0 6 9
­1 k
r o w
t e N
Bill's Office
100'
Multilin 565 Feeder Manage ment Rel ay at m ain powe r feed
d u a b
0 0 4 2
­2
Assembly Line Area
k
r o w
t e
600'
N
Multilin 269+ Motor Relay
Network 4 - 19.2 kbaud
Network 3 - 19.2 kbaud
400'
Terminating Resistors
550'
SR469 Motor Management Relay
Mu lti lin 239 Mo tor P r otection Relay
RS-485 Port A
Modbus Monitor #2
GHO Corp Machine Shop ­network wiring diagram
SR750 Feeder Management Relay
550'
300'
Lathe Area
300'
RS-485
RS-485
Port A
Port B
Modbus Monitor #1
Ma chinin g Area
Modbus Concentrator
RS-485 Port B
POWER LEADER EPM
750'
400' Spectra ECM
300'
350'
Millin g A rea
EPM 3720 Electronic Power Met er
EMVT-C Trip Unit
250'
250'
50'
Figure 27. Floor layout for Case Five.
Confident that his new design will provide maximum performance and with his wiring requirements and limits
33
Power Management Control System
Chapter 2 – Network Design
met, Bill selects Modbus addresses for the IEDs. He checks Section 2-7 and sees that he can assign the Modbus IEDs on each network any Modbus address between 1 and 247 (except for the Modbus Concentrator, which must have an address between 1 and 32). The commnet IEDs must have Modbus-equivalent addresses between 33 and 247. He selects addresses and records them for future reference. The address chart is shown in Table 12.
RS-485
Network #
1 Multilin 565 Power intake
2 Multilin 269+ Assembly line 01 3 SR469 Motor
3Modbus Monitor
3 Multilin 239
3Modbus Monitor
4 Multilin SR750
4 EPM 3720 Milling area 02 4Modbus Monitor
4Modbus Monitor
4Modbus
4 EMVT-C trip unit Machining area 33 4 Spectra ECM Machining area 34 4POWER
IED Type Physical
Location
area
Assembly line 01 Management Relay
Lathe area 02 #1, RS-485 Port A
Machining area 03 Motor Protection Relay
Machining 04 #2, RS-485 Port A
Milling area 01 Feeder Management Relay
Lathe area 03 #1, RS-485 Port B
Machining area 04 #2, RS-485 Port B
Machining area 05 Concentrator
Machining area 35 LEADER EPM
Modbus Address
01
to the next, terminated at both ends of each RS-485 network, double-checking his wiring against the example provided in Section 2–4. Sinc e sever al of his Multilin IEDs have two ports, he is careful to connect only one RS-485 port per IED. The Modbus Monitors are also RS-485 dual­port, but Bill carefully follows the wiring instructions to correctly connect them to the RS-485 networks. The A port of each Monitor is connected to one RS-485 network and the B port of each is connected to another network.
He must also bear in mind proper shield-grounding considerations: each RS-485 IED grounded at only one point and no two IEDs’ grounds connected (Rule 4, Section 2-4). The Multilin 565 special grounding considerations are also taken into account (see Chapters 2 and 3).
Bill assigns a Modbus address to each IED. He then sets communication speeds and functional and protective parameters according to the instructions in each user manual.
Bill installs the PMCS software at the host PC and configures IED addresses at the host to match the addresses assigned to each IED on the network.
Configuration files for the Modbus Monitors are downloaded to the units or created using the Monitor’s “Create from PMCS” feature (see DEH-027 for detail s).
When all connections have been made and the IEDs and software are appropriately configured, Bill applies power to the system and runs tests to assure that everything is functioning properly.
If any difficulties are encountered, Bill refers to the trouble-shooting guide in Chapter 4.
Table 12. IED Addresses for Case Five.
Chapter 3 provides Bill with physical wiring requirements and rules. He’ll use Belden 3074F cable, readily available. He also locates the correct terminating resistors at both ends of each RS-485 network.
He installs the IED s according to the instr uctions in each IED’s user manual. He then makes connections to the RS­485 communications cable in daisy-chain fashion, one IED
34
Power Management Control System
Chapter 2 – Network Design
(This page left blank intentionally.)
35
Power Management Control System
Chapter 3 – Network Wiring and Construction

Chapter 3. Network Wiring and Construction

Once the network h as been carefu lly laid out on paper and IED addresses have been planned, you need to check the following wiring requirements before beginning assembly of the system .
WARNING: Network wiring and grounding rules described herein apply primarily to commercial and industrial installations. Substation installations will exist in the presence of dangerously elevated ground potential relative to points outside of the station grid as well as large electromagnetic induction fields. Additionally, large ground faults can elevate substation ground potentials. Follow local utility best-practices and safety procedures to prevent risk of shock or electrocution to personnel and damage to equipment that could result in a loss of protection and communications.
CAUTION: The recommended installation practice is to implement optical fiber for connections between buildings to provide electrical isolation. This eliminates harmful ground loops caused by differences in the ground potential between structures.
CAUTION: Data line surge protection is recommended for network components such as hubs, computers, or modems connected to IEDs w ith copper wire, especially installations where the data communication cable is exposed (i.e., not encased in conduit) or runs parallel to power conductors. PMCS IEDs are routinely installed in areas exposed to heav y electromagnetic fields (EMF), which can induce damaging surges in data communication lines. Data line surge protection is not required for fiber optic connections.
37
Power Management Control System
Chapter 3 – Network Wiring and Construction

3–1 Wiring Requirements

Each type of network (Ethernet, Modbus, and commnet) has unique wiring requirements. These rules are summarized in Table 13. Further detail is provided following the table.
Network Wiring Required Shield Grounding Termination
Ethernet 10Base-T or 10Base-FL
CAT-3, 4, or 5 UTP, Rated 300V. A 600V requirement may be satisfied by applying 600V tubing to the ca ble .
Modbus Indoors/outdoors in conduit above grade
Belden 3074F – Data Tray 600 V industrial twinax 18 AWG (7X26); or
Belden 9841 – 300 V Communicat ion cable 24 AWG (7X32); or
Alpha 6412 – 300 V Communicat ion cable 24 AWG (7x32).
NOTES: Use one of the above approved cables that meet the NEC and UL requirements for the applic ation. A 600 V requirement may be satisfied by using the Belden 3074F or by applying 600 V tubing to either the Belden 9841 or Al pha 6412. No substitutions are permitted.
See 10Base-T or 10Base-FL wiring standards. C he c k with your LAN administ rator.
Each RS-485 network should be grounded at the host and at the RS-485 OUT port of each IED, with no continuity between wire-segm e nt shields. (See Section 2–4, rule 4)
WARNING: The National Electrical Code (NEC) and all applicable local codes must be followed when installing wiring.
See 10Base-T or 10Base-FL wiring standards. C he c k with your LAN administ rator.
The RS-485 cables must be terminated at each end of the network. The terminator
should be a 120-ohm, resistor, 5%. (See section ti t l ed Termination in this chapter for specific details on Connect Tech RS-485 card and Ethernet Gateway.)
1
/2
-watt
Commnet Indoors/outdoors in conduit above grade
Belden 8719 – 600 V shielded instrumentation c able , 16 A WG (19X29).
Below-grade applications
Belden 83702.
5
Belden 83702 is rated for d irect burial a nd air plenu m, non-co nduit app lications, but the length li mits for this ca ble are two-third s of the lengths
specified in the configuration rules of C hapter 2.
5
Table 13. Wiring requirements.
Each commnet segment’s cable shield must be grounded at the Modbus Concentrator at the port to which it is connected.
N/A: no termination is needed on commnet segments.
38
Power Management Control System
Chapter 3 – Network Wiring and Construction

Type of Wire

Ethernet
10Base-T applications may use any appropriate C at e gory 3, 4 or 5 UTP cable, provided it is rated at least 300V. Category 3 cable is sufficient for 10 Mbps applications such as PMCS. Category 5 cable supports 100 Mbps network applications. Category 4 cable is not widely available, having been superseded by Category 5 cable in the marketplace. Any of these cables may be used in 600 volt applications by applying 600V tubing to the cable.
Modbus
Belden 9841 or Alpha 6412 may be used for applications under 300 V that are indoors or outdoors in conduit above grade. These cables may be also be used for 600 V requirements by applying 600 V tubing to them. Belden 3074F may be used for applications greater than 300 V which are indoors or outdoors in conduit above grade.
Commnet
Belden M8719 shielded instrumentation cable #16 AWG wire (shielded, twisted-pair) is recommended for commnet wiring for applications indoors or outdoors in conduit above grade.
for its four RS-485 ports. No terminating resistor is needed at the POWER LEADER Ethernet Gateway.
See Figure 9 for an example of the cable run terminated at the final IED on the network.

Shield Grounding

Modbus
The RS-485 cable shield must be grounded at only a single point on each RS-485 wire. Connect the shield to the ground terminal at the Ethernet Gateway or RS-485 interface card. Connect the cable shield to the shield terminal at each IED on the RS-485 network except the Multilin 565, which does not have isolated communication ports (Modbus Rule 5, Sectio n 2–4).
Commnet
The commnet cable shield must be grounded at only a single point in each commnet segment. This is done at the POWER LEADER Modbus Concentrator. Each commnet port on the Modbus Concentrator ha s a ground terminal, and each commnet segment should be grounded at the port to which it is connected.
For below-grade applications, Belden 83702 shielded 16 AWG cable is recommended. Belden 83702 is rated for direct
burial and air pl enum, nonconduit application s, but the length limits for this cable are two-thirds of the lengths specified in the configuration rules of Section 2-1. For example, a network
segment connecting u p to four IEDs may h a ve a total cable length of no more than 667 feet of Belden 83702, versus the 1000-foot limi t on total cable lengt h fo r Be ld en 8719.

Termination

RS-485 cables must be terminated at each end of the
1
/2
network with a 120-o hm,
IMPORTANT NOTE FOR CONNECT TECH CARD USERS: The Connect Tech RS-485 card
recommended for use with PMCS systems requires a 600-ohm rather than a 120-ohm resistor. Use the 600-ohm resistor at the Connect Tech card only. The other end of the Modbus network(s) s hould be terminated with the usual 120-ohm resistor.
IMPORTANT NOTE FOR ETHERNET GATEWAY USERS: The POWER LEADER
Ethernet Gateway provides internal termination
-watt, 5% tolerance resistor.
Figure 28 shows a POWER LEADER Modbus Concentrator connected to a series of commnet IEDs. The shield of the cable to the downstream IEDs is grounded at the Modbus Concentrator on its internal shield-ground terminal strip.

3–2 Modbus – Commnet Integration

The rules regarding the number of IEDs per Modbus Concentrator and wiring-distance limits are explained in Chapter 2. The rules expressed in this section are more low-level and concern the physical connections of commnet IEDs to a Modbus Concentrator. You must follow these rules to provide for proper shielding and communications.

Wiring Concerns

No commnet segment should have more than one wiring connection at any point, such as the Modbus Concentrator, a Junction Box, or a Repeater. You must avoid this condition, which is known as looping.
Examples of correct wiring conditions and various illegal looping conditions are illustrated in Figure 28 through Figure 32. Figure 28 illustrates correct commnet wiring. Figure 29 through Figure 32 show illegal looped wiring. You can correct looping by r emoving either of the looped connections indicated by the large Xs in the figure.
39
Power Management Control System
Chapter 3 – Network Wiring and Construction
You must never connect a single commnet segment to the Modbus Concentra tor at more than one point or to more than one port on the Modbus Concentrator.
Figure 28 represents the correct wiring scheme for a commnet segment – linear, one IED to the next, connected to the concentrator at one port only.
Figure 29 through Figure 32 show various incorrect wiring schemes – commnet segments that are ‘looped’ and nonlinear. Avoid these wiring situations as they will cause communicat ion errors.
g
POWER LEADER
Modbus Concentrator
Commnet Conne ctions
Commnet Conne ctions
- + Shld - +Shld - +Shld - +Shld
X
or
X
commnet
IED
g
POWER LEADER
Modbus Concentrator
commnet
- + Shld - + Shld - +Shld - + Shld
IED
Commnet Connec tions
Commnet Connec tions
Sh ield Groun d
comm n et
IED
commnet
IED
Figure 28. Commnet shield grounding wired correctly.
g
POWER LEADER
Modbus Concentrator
commnet
IED
Commnet Conne ctions
Commnet Conne ctions
- + Shld - +Shld - +Shld - +Shld
X
commnet
IED
or
comm n e t
IED
X
comm n e t
IED
Figure 29. Incorrect wiring. Looping on one Modbus
Concentrator commnet port.
comm n e t
IED
commnet
IED
comm n e t
IED
comm n e t
IED
Figure 30. Incorrect wiring. Looping to two Modbus
Concentrator commnet ports.
To
Modbus
Concentrator
Commnet Segment
commnet
IED
POWER
LEADER
Jun ction /Outle t Box
X
commnet
IED
X
or
commnet
IED
commnet
IED
Figure 31. Incorrect wiring. Looping on segment
connected to Junction Box.
In
POWER LEADER
Repeater
Out
X
or
commnet
IED
commnet
IED
Commnet
Segment
commnet
IED
To
Modbus
Concentrator
X
commnet
IED
Figure 32. Incorrect wiring. Looping on segment
connected to POWER LEADER Repeater.
40
Power Management Control System
Chapter 3 – Network Wiring and Construction

3–3 Modbus – Ethernet Integration

Ethernet comes into play only as an alternative platform for the host PC. It is most often used when an existing Ethernet network is in place or being installed for data­networking purposes, or when Ethernet-only devices such as the EPM 7700 are to be used wit h PMC S .
To communicate with the Modbus networks (and any commnet segments beneath them), a host PC based on Ethernet requires an Ethernet Gateway. Rather than use an RS-485 interface card, connect the Modbus networks to the RS-485 ports on the Ethernet Gateway, which is connected to the Host PC via Ethernet, over which it communicates data from the Modbus networks.
The Ethernet Gateway offers a more nearly plug-and-play format, with fewer wiring complexities and rules than the Modbus Concentrator. See GEH-6505, Ethernet Gateway User Guide, for detailed information on installing and configuring the Ethernet Gateway.

3–4 Local Configuration of IEDs

You must properly configure each IED connected to the PMCS. Be sure to set th e I ED address a t the I E D and at the host software, set the communication speed, and configure any necessary settings.
For detailed directions on setting addresses, communication speed, and protection parameters, refer to the user guide for each IED.

3–5 Applying Power to the System

WARNING:
Voltages hazardous to personnel and equi pment may be present at the power connections.
Once you’ve installed the PMCS network, you should apply power to the network from the bottom up. Follow this procedure when applying power to the system for the first time:
1. Make sure that all communications wiring has been correctly connected to each IED and that the system matches the plan exactly, meeting all rules and requirements explained in this manual.
2. Make sure that all wiring for control power to IEDs has been correctly installed and that the correct control voltage is present at each IED.
3. If commnet IEDs are installed, apply control power to the IEDs and then to the M o db u s Concentrator to which they are attached.
4. Apply control power to any Modbus RTU IEDs.
5. Apply control power to the Ethernet Gateway, if one
is being used.
6. Turn the computer on and start the PMCS software according to the instructions in the software manuals.

3–6 Software Loading and Startup

Refer to the Power Management Control System software installation procedures i n GEH- 6514, Read Th i s Book First.
41
Power Management Control System

Chapter 4 – Trouble-Shooting

Chapter 4 –Trouble-Shooting
This chapter presents basic trouble-shooting procedures for PMCS networ ks. It is not mean t to be a compreh ensive guide covering every possible contingency, but will help to resolve the most common difficulties. If the information presented here does not resolve the problem, contact a Resolution Engineer at the GE Resolution Center, at 1-888­GE-RESOLV.

4–1 Communication Network Trouble-Shooting

One of the most useful tools for trouble-shootin g network problems is a one-line diagram. The following procedure uses such a diagram.
Obtain a one-line diagram of the system.
1.
Verify that none of the Modbus network
2.
configuration rules, detailed in Chapter 2, have been violated.
If POWER LEADE R commnet IEDs are attached to
3.
the network via Modbus Concentrators, you must check their configuration as well. Examine each Concentrator and its attached commnet IEDs to verify that none of the commnet network configuration r ules d etailed in Chap ter 2 have b een violated.
If the network complies with these rules, or has been modified to comply with them, and problems persist, continue with the remaining steps.
some IEDs, continue with step 5; otherwise, go to step 6.
5. Establish a p a tte r n for the IED s that do not resp ond. Are all the IEDs with problems Modbus IEDs? Are they all commnet IEDs? Are they all on one RS-4 85 network or a single commnet segment, or are they located on different networks or segments? Do all the IEDs on a segment up to a certain point communicate, while IEDs after that point do not?
If communication ca nnot be es tablishe d with any of the IEDs on a network, go to step 7.
6. If the error is limited to certain IE Ds, the foll owing checklist should help you isolate the problem.
• The IED is powered up.
• The IED’s communication settings match those
of the network it is on (baud rate, parity, stop bits).
• The IED’s address has been assigned.
• The same address is not assigned to another IED.
• The network connect ions are good.
7. If the network has no repeaters, go to step 8. For commnet segments with Repeaters, you can
localize the problem by checking all repeaters for red LEDs, which indicate disabled segments. Each repeater should have one LED lit on each input and output (either red or green). If more than one LED is lit or if none of the LEDs are lit, refer to the trouble-shooting section of the repeater manual.
4. Determine if any communication is possible. Select a Modbus IED whose wiring connections you have checked from the host to the IED and attempt communication from the host to the IED. If no communication can be established, check that the communication settings for the RS-485 network match those set at the IED and that the Modbus address at the IED matches the address assigned at the host. Reattempt communications.
Communication with an IED connected to an RS­485 network requires that it have a Modbus address. Addresses are assigned during IED setup. After the IED address has been assigned, it must be entered into the host computer. Commnet IEDs must be assigned Modbus-equivalent addresses at the Modbus Concentrators and commnet addresses at the IED. Refer to each IED’s instruction manual for detailed procedures. When the address is entered at the host, the host w ill attempt to communic ate with the IED. If commun ication can be established w ith
NOTE: If other IEDs are connected to the segment, the status LEDs may glow dimly when the cables are connected, even though the POWER LEADER Repeater is not powered.
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Power Management Control System
Chapter 4 – Trouble-Shooting
8. When the error has been localized to one RS-485 network, commnet segment, check that control power is available to every IED requiring it. If control power to certain IEDs is disconnected or turned off, it may disable communications on that segment.
9. If all the IEDs on the network or segment have control power and the error persists, disconnect all the IEDs except the Repeaters. If practical, disconnect the IE Ds one at a time to s ee which IE D is causing th e e rror.
10. If it is not possible to test communication as each IED is disconnected, check the Repeaters with all other IEDs disconnected. Both green LEDs should be lit on every Repeater. If a red LED is lit, it may indicate that the COMM shorted somewhere on that segment. Refer to the trouble-shooting section of the Repeater manual if both green LEDs are not lit.
11. If all Repeaters on the commnet segment show two green LEDs when connected to the commnet cable, the error is probably ca used by one of the IEDs on the segment. Connect the IEDs one at a time, establishing communication with each one. Refer to the IED instruction manuals for procedures for communicating with each IED.
+ and COMM lines are

4–2 Host Trouble-Shooting

If the procedure for communication network trouble­shooting does not isolate the problem, use the following procedure to determine if the host is at fault.
1. If the host is at fault, it pr obably will not be abl e to communicate with any IED. If this host can communicate with one or more IEDs, return to Section 4-1.
2. Check that power is connected to the network interface card in the host PC; if you are using an Ethernet Gateway, make sure that its control power is connected. Ensure that the Ethernet network interface card in the Host PC is properly connected and seated in its expansion slot.
3. If using an RS-485 interface card(s), check that the card(s) is seated properly in its slot and that the proper terminating resist o rs are appli e d.

4–3 IED Trouble-Shooting

To determine if an IED is causing network problems, disconnect it from the network, then refer to the appropriate user manual for the trouble-shooting procedure.

4–4 Equipment Trouble-Shooting

To determine if a section of equip ment is cau sing networ k problems, disconn e c t it f r om th e n e tw ork, then refer to the appropriate user manual for the trouble-shooting procedure.

4–5 Product Service Procedure

Call the GE Resolution Center at 1-888-GE-RESOLV if you have any additional questions or problems.
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Power Management Control System
Chapter 4 – Trouble-Shooting

4–6 Trouble-Shooting Guide

Symptom Possible Cause Corrective Action
No communication to
1.
any IEDs on the network.
(RS-485 host only) 5.
(Ethernet host only) 6.
Host PC not powered. Check that the host PC has control power and is
1. running correctl y (no PC error conditions exist).
2. Windows 2000 SP2 not
running correctly.
3.
PMCS not properly
installed or not properly configured with IED addresses and communication settings.
DDE Server not running. Check that the DDE Server is correctly installed and
4.
RS-485 interface installed
incorrectly or not functioning.
Ethernet network down
or improperly connected.
Check that Windo ws 2000 S P2 is properly installed and running correctly (no crashes or system lock ups).
Check that PMCS is correctly installed and running and has been configured with the Modbus addresses and communication settings of all attached IEDs.
running. Ensure that the RS-485 card or RS-232/RS-485
converter is properly installed at the host PC and that the RS-485 cables are correctly attached to the i nt e rfac e card or converter.
RS-232/RS-485 converter: Ensure that the DIP switches inside the converter are set properly for the baud rate of the RS-485 segment. See the convert e r documentation for further informat ion & instructions.
Check the connections at the host PC Ethernet card for loose or improper connections. Check with LAN personnel for network-wide problems that might be affecting the Ethernet Gateway or host.
(Ethernet host only) 7.
(EPM 7700 only) 8.
Ethernet Gateway not
powered, not connected to Ethernet or RS- 485 ports, or connected but improperly configured.
Device communication
settings are incorrect.
Check that the Ethernet Gateway has control power and is properly connected to the Ethernet and to the RS-485 ports. Make sure that t h e Gateway has been properly configured for t h e attached RS-485 netwo rk s.
Refer to the XPRESS Card manual that accompanied your meter. PMCS Ethernet connections require the following XPRESS C ard se ttings:
1.
An IP address (mandatory)
2.
A subnet mask (network-dependent option)
3.
A default gateway (optional; required to
communicate between networks)
4.
IP port numb er must be set to 7700 (mandatory)
5.
Use the ION protocol (mandatory)
44
Power Management Control System
Chapter 4 – Trouble-Shooting
Symptom Possible Cause Corrective Action
(EPM 7700 only) 9. Network configuration is
incorrect.
(EPM 9450Q / 9650Q with Ethernet opt ion only)
(EPM 9450Q / 9650Q with Ethernet opt ion and acting as an Ethernet Gateway only)
10. Device communication settings are incorrect.
11. Device communication settings are incorrect.
Refer to the following PMCS techni c a l d o c u mentation:
1.
DEH-40035, GE 7700 Gateway Use r’ s Guide,
section tit l e d “EPM 7700 Network Config uration.”
2.
GEH-6514, the PMC S Read -This-Book-First, se c t ion
titled “Configuring the EPM 7700 De vice Network.”
Using the EPM 9000 Seri e s Communicat or software check device profile:
1.
A device IP address (Host address)
2.
Device Port set to 502
3.
A subnet mask (network-dependent option)
4.
A default gateway (optional; required to
communicate between networks)
Check that the Ethernet Gateway Port of the EPM 9450Q/9650Q Gateway is wired t o each Modbus device Port 1.
Using the EPM 9000 Seri e s Communicat or software check device profiles:
The pass through baud rate setting of EPM
1. 9450Q/9650Q Gateway must match the baud rates of all Modbus devices
No communication to
2.
one or more Modbus IEDs; some IEDs OK.
2.
All Modbus devices must have unique addresses.
The IED or a repeater is
1. not powered.
2. RS-485 wiring is shorted or improperly connected.
3.
An RS-485 shield has
been grounded incorrectly.
The network
4. configuration is incorrect.
5.
The IED is not addressed. Ensure that each IED’s Modbus address corresponds to
Check that control power is suppli e d t o all IEDs and repeaters. If the IED or repeater does not operate when control power is present, contact the GE Resolution Center at 1-888-GE-RES OLV.
Locate and remove the short or incorrect connection.
Refer to Section 2–4, Rule 5 for proper RS-485 grounding consi d erations. Recheck th e RS-485 network for compliance. Improper grounding can cause communicat ion errors.
Check that the network conforms to Rules 1 through 8 regarding RS-485 wi ring in Chapter 2.
the address set at the PMCS.
45
Power Management Control System
Chapter 4 – Trouble-Shooting
Symptom Possible Cause Corrective Action
No communication to
3.
any IEDs on one commnet segment.
6. Two or more Modbus
IEDs have the same address.
The IEDs or a Repeater
1. on that segment is not powered.
2. Commnet wires are shorted or improperly connected.
3.
The network
configuration of the segment is incorrect.
Check IEDs for duplicate address assignment s. C h ang e the address of the affected IED, then attempt to communicate with the original address to see if another IED has that address.
Check any dual-port IEDs to be sure that each RS-485 port is wired to a se parate RS-485 network.
Check that control power is suppli ed to all IEDs. Check that two LEDs are lit on each Repeater, indicating that control power is present. If the IED or Repeater does not operate when control power is present, contact the GE Resolution Center at 1-888-GE-RESOLV.
Locate and remove the short or incorrect connection.
Check that the segment conforms to Rules 1 through 5 in Chapter 2 regardi ng the number of IEDs permitted per commnet segment and wiring requirements and limitations.
46
Power Management Control System
Chapter 4 – Trouble-Shooting
Symptom Possible Cause Corrective Action
No communication to
4.
one or more commnet IEDs.
Intermittent communi-
5.
cation to an IED (Modbus or commnet).
The IED or a Repeater on
1.
that segment is not powered.
2. The IED is not addressed. Set the commnet address at the IED and configure the
Two or more IEDs on the
3.
Modbus Concentrator have the same address.
The network
1.
configuration is incorrect.
2. The IED or a Repeater is
not powered or has inconsistent power.
Check that control power is suppli ed to all IEDs. Check that two LEDs are lit on each Repeater, indicating that control power is present. If the IED or Repeater does not operate when control power is present, contact the GE Resolution Center at 1-888-GE-RESOLV.
Modbus Concentrator to recognize the IED and assign it a Modbus-equivalent address. Enter the Modbus­equivalent address into the PMCS.
Check the Modbus Concentrator and IEDs for duplicate address assignments. Change the address of the affected IED (at the IED and the Concentrator), then attempt to communicate with the original address to see if another IED has that address.
Check that the network conforms to the rules in Chapter 2.
Check the control power supplied to the IED and to any Repeaters on the network or segment.
3.
Two or more IEDs on the
network have the same address.
Check the host for duplicate address assi g nm ents. Change the address of the affected IED, then attempt to communicate with the original address to see if another IED has that address.
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Power Management Control System
Chapter 4 – Trouble-Shooting
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48
Power Management Control System

Overview

A power management system consists of a host IED connected via a communication network to metering and protective IEDs. PMCS supports up to 256 RS-485 Modbus RTU communication networks, to which are attached various po we r m a nagement IEDs. Each RS-485 network is capable of supporting up to 247 IEDs on up to 4000 feet of interconnecting shielded, twisted-pair cable per network. The ne tw or k p rotocol is peer-to-peer , contention-sensing, multiple-access, collision-detection (CSMACD).
This appendix lists the features and functions of various IEDs that are compatible with Power Management Control System. The title bar above each IED gives its name and its general function. This is followed by a brief description of the IED and its features and functions.

239 Motor Protection Relay

The 239 relay is designed to fully protect three-phase ac motors against conditions that can cause damage. In addition to motor protection , th e r elay has fea ture s that can protect associated mechanical equipment, give an alarm before damage results from a process malfunction, diagnose problems after a fault, and allow verification of correct relay operation during routine maintenance.
Using the Modbus serial communications interface, motor starters through out a plant can be c on nected to a central control and monitoring system for continuous monitoring and fast fault diagnosis of a complete process.
Appendix A – IED Descriptions
Application
Small- to medium-sized motors
Pumps, conveyors, compressors, fans, sawmills,
mines
Variable-frequency drives
Protection
Overload (15 selectable curves)
Phase short circuit
Locked rotor/mechanical jam
Thermal memory lockout
Single phase/unbalance
Ground fault
Overtemperature: thermistor
Additional three RTDs optional
Undercurrent
Trip/alarm/auxiliary/service outputs
Five switch inputs
Monitoring and Metering
Status/current/temperature display
Process control
Optional analog output
Simulation mode for field testing
User Interface
RS-485 Modbus communications
40-character illuminated display
Six LED indicators
Keypad
Features
ac/dc control power
Compact size, fits most motor starters
NEMA12/IP53 enclosure
One relay is required per motor starter. Setpoints are entered via the f ront panel or with a computer. Status, actual values, and trouble-shooting information are available in clear English from the front-panel display. A simulation mode and pickup indicator allow testing and verification of cor rect operation without r equiring a relay test set.
With the use of the RTD option , up to three RTD s can be monitored. These can all be in the stator or one in the stator and two in the bearings . An optional analog output is also available for direct PLC interface or metering of the motor thermal capacity.
Installing a 239 relay in a motor starter for protection and monitoring of small- to medium-sized motors will minimize downtime due to process problems.

269+ Motor Management Relay

The 269 Plus Motor Relay provides complete, accurate protection for industrial motors and their associated mechanical systems, offering a wide range of protection, monitoring, and diagnostic features including the following (functions with an asterisk require the optional Meter Transducer Module):
Metering
Currents (Ia, Ib, Ic)
Ground Current
Voltages* (Va-b, Vb-c, Vc-a)
kW*, kVAR*
Power Factor*
49
Power Management Control System
Appendix A — IED Descriptions
Running MWHr*
Frequency
Protection
Overload
Short Circuit
Rapid Trip
Immediate Overload
Current Unbalance
Ground Fault
Overtemperature
Overvoltage
Undervoltage
Power Factor
Undercurrent
Thermal Capacity

565 Feeder Management Relay

The 565 feeder management relay is designed to provide complete and accurate feeder protection, providing the following functions (functions with an asterisk require the optional Meter Transducer Module):
Metering
RMS phase and ground current
Phase volts
Peak amps demand
Frequency
Power factor*
kW*, kVAR*, kWHr*
Peak kW*, kVAR demand*
Protection and alarm
Phase and ground-overcurrent
Current unbalance
Overvoltage
Undervoltage
Power factor*
Under/Over frequency*
Peak Amps, kW*, kVAR* demand
Undercurrent
Thermal capacity

735 Feeder Relay

The 735 is a microprocessor-based relay for primary circuit protection on distribution networks at any voltage level. Protection features include three-phase
timed overcurrent, phase instantaneous overcurrent, ground timed overcurrent, and ground instantaneous overcurrent. Each protection element can be selectively enabled with the front-panel dial settings. Flexible settings and selectable curve shapes enable accurate coordination with other IEDs. Installation and maintenance costs are lower when the SR735 is used instead of the eight separate over-current protection IEDs it can replace.
The SR735 has three output contacts: trip, auxiliary trip, and service required. The auxiliary trip may be set to follow the main tr ip rela y, act a s a n 8 6 Lock out re lay, or to respond only to ground-overcurrent faults, while the main trip responds only to phase-overcurrent faults.
The SR735 has eight trip indicators on the front panel, along with a button to reset the relay. Four status indicators provid e a quick vis ual che ck of rel ay s tatus. A bar graph indicates current load as a percent of CT rating.
Communications switch es on the front panel set baud rate, relay a ddr ess , an d th e simu lation mode f or tes ting. An RS-485 connection is provided for computer access. Software is provided with the relay to allow setup and simulation testing.
Computer access allows the display of a trip record, which contains the pre-trip currents and the last five trip conditions. Computer access also allows the display of metered current values as a percent of CT rating, output relay status, status indicat o rs, and dial settings.
The SR735 has a drawout construction and can be door or 19-inch rack mounted.
Application
Feeder protection, any voltage level
Protection and Co nt r o l
Three-phase time overcurrent
Ground time overcurrent
Five curve shapes
Four curve-shift multipl iers per curve
10 time multipliers per curve
ANSI, IAC, or IEC/BS142 curves
Phase instantaneous overcurrent
Ground instantaneous overcurrent
Pickup level for each overcurrent
Outputs: trip, aux. trip, service
Aux. trip: 86 lockout, ground trip
Block instantaneous on autoreclose
Monitoring
50
Power Management Control System
Appendix A – IED Descriptions
Trip record of last five trips
Pre-trip data includes currents
True RMS sensing
Monitor currents, output relays, status, setti ngs
User Interface
Eight LED trip indicators
Four LED status indicators
Current bar graph, percent of CT rating
RS-485 communicati ons
Modbus RTU protocol
Baud rate up to 19,200
Software for setup and simulation
Features
1 amp or 5 amp CT input
20–260 V ac/dc control power
Drawout case
Switchgear door or 19-inch rack mount

MX200 (Microprocessor Controller)

GE Zenith Controls MX200 advanced microprocessor controller is designed for the most demanding transfer or bypass switch applications. It may be specified with standard options or programmed to use any or all of the most commonly used options for today's transfer switch operation. It also may be equipped with our ZNET200 remote communication interface for use with annunciators, modems or PC control.
Built-in diagnostics with displays for ease of
troubleshooting
Passcode protected to limit user access
Timer countdown display for ease of operation
User settings unaffected by power outages
Wide range of accessories and configurations
available for the most demanding applicati o ns
Design and Construction Features
Close differential three-phase under-voltage
sensing of the normal source—factory standard setting 90% pic kup, 80% dr opout (adjusta ble); under-frequency sensing of the normal source factory setting 95% pickup (adjustable)
Voltage and frequency sensing of the
emergency source—factory standard setting 90% pickup voltage, 95% pickup frequency (adjustable)
Tes t switch (f ast te st/loa d/n o load ) to s imulate
normal source failure—automatically bypassed should the emergency source fail
Type 1 enclosure is standard; also available in
open style or Types 3R, 4 or 12
Double-throw, mechanically interlocked
contactor mechanism
Electrically operated, mechanically held
Designed for emergency and standby
applications
The MX200 manages switch operation via a convenient touchpad that provides indication setting and diagnostic capabilities. As an embedded digital controller, the device offers high reliability and ease of unattended operation across a range of applications.
The GE-Zenith MX200 (Microprocessor offers the following features:
Multipurpose display: LEDs for continuous
monitoring of switch position and source availability; a four-line by 20-character, backlit LCD display for settings, functions, programming and annunc iation
Through-the-door programming and display
Simplified keypad entry—menu-driven system
is designed for ease of use

Generator PLC (Series 90-70)

The Generator PLC is configured in such a way that Master PLC has all the information of all the 16 Generator Parameters.
The Generator PLC offers the following features:
Metering and Monitoring
Metering: A, V, W, var, Hz
Generator Parameters
Paralleling Switch gear parame ters

Electronic Power Meter EPM 7330

The EPM 7330 gives you all the high-accuracy measurements of the EPM 7300, plus on-board data storage, setpoints, standard digital I/O and an optional Ethernet port and optional built-in modem either of which can be used as a gateway to as many as 31 serial devices.
51
Power Management Control System
Appendix A — IED Descriptions
Applications Summary
Cost Allocation & Billing
Demand & Power Factor Control
Load Studies & Circuit Optimization
Equipment Monitoring & Control
PreventativeMaintenance
The EPM 7330 offers the following features:
Measurements
Energy: bi-directional, absolute & net
Demand: Sliding Window, Predicted, &
Thermal
Harmonics: individual & total harmonic
distortion up to the 15th
Communications
allows distribution of metered data and alarms
over the Internet
1 Option al built-in modem allows access to up
to 31 RS-485 devices
1 Optional Ethernet port with EtherGate™,
allows access to RS-485 device ne t works
2 RS-485 ports
1 front panel optical port
Modbus™ RTU on serial, Ethernet, modem, &
infrared ports
DNP 3.0 on serial, modem, & infrared ports
On-Board Data Logging
Scheduled or event-driven logging of up to 32
parameters
Sequence-of-events & min/m a x logging
Setpoints for Control and Al arms
Setpoint on any parameter or condition
1 second operation
Inputs and Outputs
4 digital inputs for status/counter functions
4 relay outputs for control/puls e fu nc tions
Optional Analog inputs and outputs
Switchboard Draw-out Cases
Fits into existing GE S1 or ABB FT21
switchboard cases.
Instantaneous Measurements
Voltage (l-l/l-n), per phase and average
Current, per phase and average
Real Power, per phase and total
Reactive Power, per phase and total
Apparent Power, per phase and total
Power Factor, (lead/lag), per phase and total
Voltage Unbalance
Current Unbalance
Frequency
Energy
Imported, exported, absolute and net kWh &
kVARh. Accumulated kVAh
Demand
Sliding Window, Predicted, and Thermal
Demand on kW, kVAR, kVA, and I average
Minimums and Maximums
Voltage (l-l/l-n) per phase
Current per phase
kW, kVAR, kVA, Power Factor, Frequency
Sliding Window Demand for kW and kVA

Electronic Power Meter EPM 3710

The Electronic Power Meter (EPM) 3710 is a 16-bit microprocessor-based digital instrumentation package for three-phase industrial, commercial, and utility power systems. The EPM 3710 offers a large array of measurements, waveform capture for harmonic analysis, and setpoint-controlled relays, including the following features:
Three-phase voltage inputs
Three-phase current inputs
Neutral/ground current input
Three relay outputs
Four digital inputs with pulse counter on one
input with maximum pulse-count frequency 0.3 Hz
One analog voltage input, one analog current
output
80 measured parameters
Waveform-capture triggering communic ation
port
Trend log with one preset log, 12 parameters,
1200-record capacity, t riggered by time interval (Optional: one programmable lo g , 12 parameters, 11,520 record capacity [40 days])
Event log with 50 records standard, one-second
resolution(opti o nal: 100 re c ords)
Minimum/maximum log with 17 parameters
17 standard-speed setpoints trigger event log or
relay control
The Electronic Power Meter 3710 offers 38 high­accuracy, real-time measured parameters, minima and maxima for 21 parameters, and 25 status parameters.
52
Power Management Control System
Appendix A – IED Descriptions
All voltage, current, power, and energy readings are true RMS, including harmonics. Energy readings provide bi-directional (import/export) indication.
No potential transformers (PTs) are required on the voltage inputs for systems up to 347 Vac line-to­neutral/600 Vac line-to-line. For higher voltage systems, PTs with 120 Vac secondaries may be used. The transformer-coupled current inputs provide 300 A surge protection and accept CTs with 5 A full-scale outputs.

Electronic Power Meter EPM 3720

The Electronic Power Meter 3720 offers the same capabilities as the EPM 3710, plus many additional measurements and more advanced features, including the following:
Three-phase voltage inputs
Three-phase current inputs
Neutral/ground curre nt input
Three relay outputs
Four digital inputs with pulse-counter on all four
inputs with maximum pulse count frequency of 10 Hz
One analog voltage input, one analog current
output
729 measured parameters, including harmonic
distortion and demand
Waveform-capture tri ggering com m u nications
port or setpoint
Waveform-recording triggering communications
port or setpoint
Eight programmable trend l ogs, 12 parameters
each, 11,520 record capacit y (40 d a ys), triggered by time interval or setpoint
Event log with 100 records standa rd , resolution
one second
Minimum/maximum logs: one preset with over
100 parameters; 16 programmable logs of 16 parameters each with a trigger parameter for each log
17 setpoints: 11 standard-speed, six high-speed;
trigger event log, relay control, snapshot log, waveform capture or waveform recorder
The Electronic Power Meter 3720 provides hundreds of high-accuracy real-time measured parameters, as well as minima, maxima, and status parameters.
All voltage, current, power, and energy readings are true RMS and sensitive to beyond the 50 Four-quadrant readings measure bidirectional
th
harmonic.
(import/export) energy flow, useful in any cogeneration application.
No PTs are required on the voltage inputs for systems up to 347 Vac line-to-neutral and 600 Vac line-to-line. For higher-voltage systems, PTs with 120 Vac secondaries may be used. The transformer-coupled current inputs provide 300 A surge protection and accept CTs with 5 A full-scale outputs.

Electronic Power Meter EPM 7300

The Electronic Power Meter 7300 provides over 100 high-accuracy, three-phase measurements. Its compact size, simple installation and high reliability make it ideal for use in panelboards, switc hboards, switchgear, gensets and UPS systems. With RS-485 communications, it can be integrated into a power management system such as PMCS.
Instantaneous Measurements
Voltage (l-l/l-n), per phase and average
Current, per phase and average
Real Power, per phase and total
Reactive Power, per phase and total
Apparent Power, per phase and total
Power Factor, (lead/lag), per phase and total
Voltage Unbalance
Current Unbalance
Frequency
Energy
Imported, exported, absolute and net kWh &
kVARh. Accumulated kVAh
Demand
Sliding Window, Predicted, and Thermal
Demand on kW, kVAR, kVA, and I average
Minimums and Maximums
Voltage (l-l/l-n) per phase
Current per phase
kW, kVAR, kVA, Power Factor, Frequency
Sliding Window Demand for kW and kVA

Electronic Power Meter EPM 7500/7600/7700

The EPM 7500/7600/7700 is a highly advanced digital power meter, suited to virtually any power monitoring and control application. This Intelligent Electronic Device (IED) can take the place of numerous transducers, meters and control circuits in a power monitoring system. The EPM 7700 provides true RMS
53
Power Management Control System
Appendix A — IED Descriptions
measurements of voltage, current, power and energy, complemented by extensive I/ O capabilities, comprehensive logging, and advanced power quality functions.
Instantaneous Measurements
Voltage (l-l/l-n), per phase and average
Current, per phase, average and neutral
Real Power, per phase and total
Reactive Power, per phase and total
Apparent Power, per phase and total
Power Factor, (lead/lag), per phase and total
Voltage and Current Unbalance
Frequency
Energy
Imported, exported, absolute and net kWh &
kVARh. Accumulated kVAh.
Demand
Calculates Demand and Peak Demand on any
instantaneous value. Defaults: Sliding Window, Predicted, and Thermal Demand on kW, kVAR, kVA, and I average
Minimums and Maximums
Any parameter over any time interv a l (e.g., daily,
monthly)
flexible backplane design of the 90/30, while offering a selection of more powerful microprocessor CPUs.
The Series 90/70 PLC offers access to a large variety of discrete and analog I/O modules. Input modules supporting eight to 32 circuits in a variety of voltages are available, as are a range of output modules. The features and functions provided by the PLC 90/70 vary depending on the options installed in the backplane. See your GE Industrial Systems sales engineer for more details on the PL C 90/30 or 90/70.
The PLC 90/30 and PLC 90/70 functions supported by the Power Management Control System include the following:
Reading of input and output tables
Reading of registers
Reading of analog inputs
Reading of exception status
Preset single registers
Force multiple outputs
Preset multiple registers
Report IED type
Read scratchpad memory

GE Fanuc PLC Micro 90

GE Fanuc PLC 90/30

GE Fanuc’s Series 90/30 Programmable Logic Controller (PLC) is a family of controllers, I/O systems, and specialty modules designed to meet the demand for a versatile industrial control. Its compact backplane design allows up to five modules to be easily snapped in for access to a large variety of discrete and analog I/O modules, as well as specialty modules. Various modules can provide control for a wide range of applications, such as high-speed packaging, material handling, complicated motion control, water treatment, continuous emissions monitoring, mining, food processing, elevator control, and injection molding. PLC 90/30 functions supported by PMCS are listed below, under the PLC 90/70 heading.

GE Fanuc PLC 90/70

GE Fanuc’s Series 90/70 Programmable Logic Controller offers a greater level of power and flexibility than the Series 90/30, and is the preferred choice for high-density input/output. The 90/70 shares the
GE Fanuc’s Series 90 Micro PLC Programmable Logic Controller offers power, flexibility, and robust construction in a compact package. The Series 90 Micro PLC is an ideal way to replace relays and automate small processes. Its all-in-one construction saves panel space and its powerful features bring productivity and cost savings to even the most cost-conscious control applications. The Micro PLC is a perfect solution for such applications as packaging, industrial machinery, material handling, and printing.

EPM 5000P/5200P/5300P/5350P

The EPM 5000P/5200P/5300P/5350P advanced multifunction monitoring system replaces all individual single-function meters and transducers. This monitor measures volts, amps, frequency and all power functions, in cluding watts, va rs, frequen cy, power, watt­hours, var/hours, demand, harmonics and more. It offers 283 readings in a standard switchboard-size footprint. The EPM 5000P/5200P/5300P/5350P also displays %THD, K factor and harmonic waveforms.
54
Power Management Control System
Appendix A – IED Descriptions
The EPM 5350P offers the following features other than in the series
Ethernet TCP/IP
The 5000P/5200P/5300P/5350P device se ries offers the following features:
Measures Volts, Amps, Watts, Vars, VA, PF,
Frequency, Watt-Hour, VA/hour, VAR/hour
Measure Harmonics to the 31st Order
Provides Captured Waveform of Voltage and
Current Set Point
Control With Logical Descriptors Relay Outputs
and Pulse Outputs Max and Min for
Ten Channels of Analog Outputs
(0-1 or 4-20mA)
KYZ-Pulse Outputs (For EPM 5200P)
MicroVersaTrip-C and -D and Spectra MicroVersaTrip Trip Units
PMCS supports three varieties of this popular line of electronic trip units: the Enhanced MicroVersaTrip-C, Enhanced MicroVersaTrip-D, and the Spectra MicroVersaTrip. MicroVersaTrip trip units act to trip the circuit breaker when one of the following user­defined parameters is exceeded (parameters identified by an asterisk are optional features of the t ri p uni t.):
Overcurrent
Long-time
Short-time*
Instantaneous
High-range instantaneous*
Ground fault*
Zone select*
Protective relays*
Overvoltage
Undervoltage
Overcurrent
Voltage unbalance
Current unbalance
Reverse power
The MicroVersaTrip trip unit is also capable of limited metering functions. It can measure current and voltage at a circuit breaker and use these to calculate other electrical parameters. Information on current is supplied by the breaker’s current sensors. Voltage information is supp lied by the equipme nt bus potentia l transformers through vo l tage conditio ne rs.
It can measure or calculate values of the following parameters.
RMS current: phases A, B, and C
RMS voltage: phases A, B, and C
Watts: phases A, B, and C
Volt-amperes: phases A, B, and C
Watt-hours: phases A, B, and C
Frequency
Power factor

Modbus Concentrator

The POWER LEADER Modbus Concentrator allows PMCS to communicate with POWER LEADER commnet IEDs. The Modbus Concentrator is an RS­485-native IED that collects data from up to 32 attached POWER LEADER commnet IEDs and communicates this data to the PMCS across the POWER LEADER Modbus communication network. In this respect, the POWER LEADER Modbus Concentrator effectively serves as the host IED on up to eight commnet networks while acting as a slave to the master-slave Modbus network.
The major functions provided by the POWER LEADER Modbus Concentrator are:
Configuration of commnet IEDs
Data collection from commnet IEDs
Processing of metering data
Demand and Energy calculations
Processing of events (trips and alarms)
Executions of commands upon host request

Electronic Power Meter (PLEPM)

The POWER LEADER Electronic Power Meter (PLEPM) is a full-function electronic meter with optional pulse initiation. The PLEPM continuously monitors specified line characteristics and shows the desired functions and calculated values on a two-line, back-lit liquid crystal display on the front panel.
The PLEPM monitors and stores values for each current and voltage input. From these values it calculates RMS voltage, RMS current, real and reactive power, and other time-based functions. Data are then sent automatically to the display.
The PLEPM monitors and displays the following electrical parameters:
RMS current (Phases A, B, C and neutral)
55
Power Management Control System
Appendix A — IED Descriptions
RMS voltage (P hases A-N, B-N, C-N, A-B, B -C, C-
A)
Watts (Phases A, B, C and total)
VARs
Volt-amps (Phases A, B, C, and total)
Power Factor, total
Watt-hours total
VARs (Phase A, B, C, and total)
VAR-Hours, Total Lag, Total Lead, and Total
Current demand
Peak current
Watts demand
Peak watts demand
Frequency Hz
The PLEPM is available in configurations accepting direct voltage inputs from 69 Vac to 600 Vac. For system voltages greater than 600 Vac external PTs must be supplied. Meter current inputs are rated at 5 amps ac nominal. External CTs must be suppli e d.

POWER LEADER Ethernet Gateway

The Power Management Control System host may be located on a PC connected to a n Ethern et. If this is the case, an IED named the POWER LEADER Ethernet Gateway is required to connect Modbus-based networks of IEDs to the Ethernet-based host PC. The POWER LEADER Ethernet Gateway is an industrial computer equipped with Modbus and Ethernet communications.
It provides an interface for transferring messages between an Ethernet network and up to four Modbus networks containing up to 31 IEDs each, serving as a “traffic controller” to pass messages between the Modbus network(s) and Ethernet network.
When the Gateway receives a message from the Ethernet or Modbus network, it trans lates the message protocol and forwards the message to the correct destination. The Ethernet Gateway converts messages from the Modbus RTU protocol to Ethernet’s TCP/IP protocol (and vice versa) directly . No interpretation or concentration of IED data is performed by the Gateway.
The Ethernet Gateway’s major functions are:
Relay data from Modbus network(s) to the
PMCS host on the Ethernet network
Deliver messages and commands from the host
to the attached Modbus and commnet IEDs

POWER LEADER Junction/Outlet Box

The POWER LEADER Jun ction/Outlet Box allows the interconnection of as many as four commnet cables to create system nodes on a commnet segment attached to the Modbus Concentrator. This is useful to economize the wiring on a given commnet segment.

POWER LEADER MDP Overcurrent Relay

The MDP Overcurrent Relay is a microprocessor-based, non-directional overcurrent relay that protects circuits from phase-to-phase and phase-to-g round faults.
Included with the MDP Overcurrent Relay are four measuring units, one for each of the three-phase currents and one for ground or residual current. Each of the four measuring units includes a time and an instantaneous overcurrent unit .
Features include:
Inverse overcurrent, including fo u r c harac ter-
istic curves and four values of definite time protection, and instantaneous overcurrent pro­tection with programmable delay.
Phase and ground current measurement.
Phase and ground current mete ring.
Operating time and fault current of the last trip.

POWER LEADER Meter

The POWER LEADER Meter measures currents and voltages in a single compartment and uses these to calculate other system parameters. The current inputs are taken from standard 5 A CT secondaries, while the voltage inputs are taken from 120 Vac PT secondaries. The following parameters can be viewed:
RMS current
RMS voltage
Watts
VARs
Volt-amps
Power Factor
Watt-hours
VAR-hours
Current demand
Peak current
Watts demand
Peak watts demand
Frequency
Harmonic distortion
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Power Management Control System
Appendix A – IED Descriptions
Waveform capture
These parameters can also be viewed at the host computer. Requests may be entered locally or from the host.
The Meter has two relay outputs that can be programmed to provide IED protection.

POWER LEADER Modbus Monitor

The POWER LEADER Modbus Monitor provides a central station for viewing metering and status information collected from multiple remote power management IEDs. The Monitor may be mounted in equipment or independently and offers two RS-485 ports for connection to one or two separate RS-485 networks. Up to two Mod bus Monitors may be installed on a single RS-485 network, providing multiple locations to view data.
Features
Easy-to-use, menu-drive n u se r interface
Large, high-visibility display
Customizable display of data
View the event log of the previous 50 events with
time and date stamp
View PMCS log – displays last 50 events logged
by the PMCS Event Logger, regardless of which network the events happened on
Universal power supply accepts 100–240 Vac,
125–250 Vdc

POWER LEADER Repeater

The POWER LEADER Repeater regenerates signals on long commnet segments and allows the range of the commnet segment to be extended beyond the 1000-foot limit. See Section 2–1 for configuration rules to create extended-range commnet segments.

Power Quality Meter (PQM)

When continuous monitoring of a three-phase system is required, the Power Quality Meter (PQM) is an ideal choice. It provides metering for current, voltage, real and reactive power, energy use, cost of power, power factor, and frequency. Programmable setpoints and four assignable output relays allow control functions to be added for specific applications. These include basic alarm on over/undercurrent or -voltage, unbalance, demand-based load shedding, and capacitor power factor-correction control. More complex control is
possible usin g the four s witch inputs , which als o can be used for status, such as breaker open or closed and flow information.
The PQM is a data-gathering IED for a plant­automation system that integrates process, instrument, and electrical requirements. All monitored values are available via two digital RS-485 communication ports running the Modbus protocol. If analog values are required for direct interface to a PLC, any of the monitored values can be output as a 4–20 mA signal to replace up to four separate transducers. A process variable can be measured using the analog input. An RS-232 communication port can be connected to a PC for simultaneous access of information by other plant personnel via the front panel .
With increasing use of electronic loads, such as computers, ballasts, or variable-frequency drives, the quality of the power system is important. With the PQM’s harmonic-analys is option, any phase current or voltage can be displayed and the harmonic content calculated. Knowing the harmonic distribution , you ca n take action to preve nt overhe ated tra nsforme rs, motor s, capacitors, and neutral wires and nuisance breaker trips. Redistribution of system loading can also be determined. Waveform and chart recorder printouts available from the PQM assist in problem diagnosis.
Applications
Metering of distribution feeders, transformers,
generators, capacito r banks, and motors
Medium- and low-voltage systems
Commercial, industrial, utility
Flexible control for demand load shedding,
power factor, etc.
Power quality analysis
Measure/Control
A, V, W, var, VA, varh, Wh, PF, Hz unbalance
A, W, var, VA demand
Load shedding
Power factor control
Communication
Ports: RS232 front, dual RS-485 rear
Modbus RTU protocol
Mini RTU: digital four in/four out
Analog one in/four out
Local/remote display of all values
Maintenance
Harmonic analysis through 62nd harmonic with
THD and TIF
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Power Management Control System
Appendix A — IED Descriptions
Event recorder
Waveform capture
Data logger

RS-485 Repeater

Repeaters extend the range of an RS-485 network. The following commercially available RS-485 repeater is recommended for use with the PMCS, in accordance with the config u rat ion rules explained in C hapter 2.
Manufacturer Description
OPTO 22 AC38 RS-485 Isolated Multidrop
Repeater
369 Motor Management Relay
The 369 is a digital relay that provides protection and monitoring for three phase motors and their associated mechanical systems. A unique feature of the 369 is its ability to "learn" individual motor parameters and to adapt itself to each application. Values such as motor inrush current, cooling rates, and acceleration time may be used to improve the 369's pro tective capabiliti es.
369 offers the following features:
AC/DC control power
Flash memory
Simulation mode for field testing
Trip/Alarm/Aux1/Aux2 Relay Outputs
Optional split mounting
Optional remote RTD module

Spectra Electronic Control Module (ECM)

The Spectra RMS Electronic Control Module (ECM) is a microprocessor-based IED that functions as an adjustable overload relay to protect motor starters in GE 8000 Line Motor Control Centers. It works in series with a Spectra RMS Mag-Break a contactor.
The ECM provides the following functions:
Electronic overload protection in coordination
with Motor Circuit Protector
User-selectable current phase-loss protection
User-selectable phase-unbalance protection
User-selectable equipment ground-fault
protection
Control voltage/u nd e rvoltage contact or coil
®
Motor Circuit Protector an d
Current metering (via commnet)
Full-load amps adjustment of 33–100% of
breaker rating plug valu e
NEC Relay Class 10/20/30 selection
Contact for monit oring trip status

SR469 Motor Management Relay

The SR469 Motor Management Relay is intended for protection and management of medium- and large­horsepower motors and driven equipment. Motor protection, fault diagnostics, power metering, and communication functions have been integrated into one complete, economical draw-out package.
The SR469 has integrated every protection feature that could be considered a benchmark for medium- and large-motor protection. This high degree of integration allows for standardization on one motor-protection relay regardless of application.
The heart of the SR469 is the thermal model. In addition to the current-protection elements, RTD inputs are provided for stator- and bearing-temperature protection. The addition of VT inputs allows for voltage- and power-protection elements. Phase­differential CT inputs are provided for phase­differential protection. All of the protection elements are self-contained and may be enabled as required. This design makes programming the SR469 a simple exercise.
The SR469 has complete monitoring and metering functions. An event recorder stores 40 time- and date­stamped records. Waveform capture of 16 cycles allows for setting the number of pre-trip and post-trip cycles recorded. The SR469 learns the acceleration time, starting current, and thermal capacity required during motor starts. If motor load during starting is relatively consistent, these learned values may be used to fine­tune the acceleration protection. The SR469 can also learn the average motor load over a period o f t i me.
The relay has compete local and remote user interface capabilities. A forty-character display, keypad, and LED indicators provide local communication. A front-panel RS-232 port provides convenient computer access. Two rear-panel RS-485 ports are provided for remote communication.
Applications
Medium and large motors
Driven equipment
Motors with high inertial loads
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Power Management Control System
Appendix A – IED Descriptions
Protection and Co nt r o l
Thermal model biased with RTD feedback and
negative sequence current
Voltage-compensated acceleration
Undervoltage, overvoltage
Phase-differential protection
Underpower for load loss
Out-of-step for synchronous motors
Dual overload curves for two-spee d m otors
Reduced-voltage starting control
Trip coil supervision for breakers
Inputs and Outputs
12 RTDs, programmable
Five pre-defined and four assignable digital
inputs
Four analog inputs
Six output relays
Four programmable analog outputs
Metering and Monitoring
A, V, W, var, VA, PF, Hz, Wh, varh demand
Event recorder – last 40
Waveform capture – 16 cycles
User Interface
22 front-panel LED indicators
40-character display
Control keys and numeric k e ypad
RS-232 and two RS-485 ports

SR489 Generator Management Relay

The SR489 Generator Management Relay provides economical protection, metering, and monitoring functions. It can be used as primary or backup protection on synchronous or induction generators of 25, 50, or 60 Hz. It may be applied in primary, backup and cogenerator applicatio ns.
The SR489 offers comprehensive generator protection features. These features include phase differential, 100% stator ground, ground-overcurrent, negative­sequence overcurrent, voltage-restrained phase­overcurrents, over- and undervoltage, over- and underfrequency and reverse power. To accommodate synchronous gener ators , the pr otection f eatur es in clude overexcitation, loss of field, and inadvertent generator energization.
Monitoring functions include RMS current, negative­sequence current, voltage, three-phase power, and temperature via 12 RTD inputs.
Voltage terminal fuse and breaker operation are monitored and failures reported.
Four analog inputs may be used for monitoring vibration or control transducers. The four analog output channels can be configured to reflect any measured parameter, and may be used to eliminate costly transd ucers. Digital inputs may be u sed to route signals through the SR489 for protection, control, or diagnostic functions.
The user interface includes a 40-character display and a keypad. Twenty-tw o LED indicators on the front-pa nel indicate status of the SR489, the generator, and the output relays. A front-panel RS -232 port allows easy local computer access. Two rear-panel RS-485 ports provide remote access. Data communication rates range from 300 to 19,200 baud. All data can be transmitted simultaneously through the three communications ports to PMCS soft ware.
Application
Synchronous or induction generators
Primary, backup, and cogenerator
Protection and Co nt r o l
Phase differential
100% stator ground
Ground overcurrent
Anti-motoring (reverse power)
Loss of field
Negative-sequence overcurrent
Instantaneous overcurrent (st a rtup)
Voltage-restrained phase-overcurrent
Overexcitation, Volts/Hz
Undervoltage and overvoltage
Voltage phase reversal
Underfrequency and overfrequency
Stator overtemperature
Bearing overtemperature, vibration
Inadvertent generator energization
Sequential-tripping logi c
Breaker-failure detection
Overspeed
VT fuse-failure detection
Trip coil supervision
Four analog outputs, four analog inputs
Seven digital inputs, 12 RTD inputs
Metering and Monitoring
Metering: A, V, W, var, VA, Wh, varh, PF, Hz
Demand values: A W var VA
Event record: last 40 event s
Waveform capture: 16 cycles
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Power Management Control System
Appendix A — IED Descriptions
User Interface
40-character display and keypad
One RS232 port, two RS-485 port s

SR745 Transformer Management Relay

The SR745 is a high-speed, multiprocessor based, three­phase, two- or three-winding, Transformer Management Relay™ intended for primary protection and management of small, medium and large power transformers.
The SR745 combines percent differential, overcurrent, frequency, and overexcitation protection elements along with monitoring of individual harmonics and THD in one economical package.
The SR745 provides a variety of adaptive relaying features. Adaptive harmonic restraint addresses the problem of fals e tripping dur ing inrus h. Adaptive time­overcurrent elements adjust their pickup settings based on the calculated transformer capability when supplying load currents with high harmonic content. Multiple setpoint groups allow you to enter and dynamically select from as many as four groups of relay settings to address the protection requirements of different power-system configurations. Dynamic CT­ratio mismatch correction monitors the on-load tap position and automatically corrects for CT-ratio mismatch. FlexLogic™ allows PLC-style equations based on logic inputs and protection elements to be assigned to any of the SR745 output s.
Simulation mode provides a powerful testing and simulation featur e. This provides the abil ity to test the relay operation based on captured or computer­generated waveform data. These data can be converted to a digitized format and downloaded into the SR745’s simulation buffer for playback.
The SR745 also provides its own waveform-capture function, which records waveform data for faults, inrush, or alarm conditions.
The autoconfiguration function eliminates the need for any special CT connections by having all CTs connected in wye.
Application
Small, medium, and large power transformers
Protection
Percent differential
Adaptive harmonic restraint
Multiple overcurrent elements
Adaptive time O/C elements
Underfrequency
Frequency rate-of-change
Overexcitation
Multiple setpoint groups
Metering and Monitoring
All currents
THD and harmonics
Demand
Percent of rated load
Harmonic analysis
Tap position
Ambient temperature
Analog transducer input
Waveform capture and playback
Simulation mode
Inputs/Outputs
Three analog transducer inputs
16 digital (logic) inputs
Seven analog transducer outputs
Nine control ou tputs
Additional Features
FlexLogic™ (programmable logic)
Auto-configuration (vector group
compensation)
Dynamic CT-ratio mismatch correction
RS-232 and RS-485 ports
Draw-out construction

SR750 Feeder Management Relay

The SR750 Feeder Management Relay is a microprocessor-based relay intended for the management and primary protection of distribution feeders. It can also be used for management and backup protection of busses, transformers, and power lines. The relay tracks the power-system frequency and adjusts the sampling rate to maintain accuracy at all times.
The relay is specifically designed as an economical feeder-management system, incorporating the requirements for protection, control, metering, and both local and remote user interfaces in one assembly. This eliminates the need for expensive discrete components.
Complete overcurrent protection is provided. This includes phase, neutral, ground, and negative-sequence
60
Power Management Control System
Appendix A – IED Descriptions
protection for time-overcurrent , hi-set overcurrent, lo-set overcurrent, and directional control. Overvoltage, undervoltage, and underfrequency functions each have two independent stages. With 14 programmable logic inputs and seven outputs, the SR750 can be easily configured for specific applications. The relay has extensive monitoring and metering functions. It has an internal memory that allows it to record the last 100 events, the last 10 faults, and a total of 256 cycles of oscillography data. The relay performs self-tests in the background during operation. A simulation function allows you to test the rela y with out th e ne ed f or e xter n al ac voltage and current inputs.
The relay has a two-line display and keypad, as well as three serial ports for c omputer interface.
Application
Industrial and utility feeders
Protection and Co nt r o l
Complete time overcurrent
Complete instantaneous overcurrent
Directional overcurre nt control
Undervoltage and overvoltage
Negative-sequence voltage
Undervoltage automatic restoration
Bus underfrequency
Underfrequency automatic re st oration
Breaker failure
Manual close control
Cold-load pickup control
Four setting groups
Syncrocheck - V, f, Hz, & dead-source
14 programmable logic inputs
Bus transfer
Monitoring and Metering
Fault locator, record o f l ast 10 faults
Breaker operation & trip failure
VT Failure
Power factor – two independent stages
Analog input – level and rate
Total breaker arcing current
Event recorder – Last 100 events
Oscillography – 256 cycles
Metering: V, I, Hz, var, VA, PF
Demand: I
Data Logger
User Interface
40-character display and 24 LEDs
, I0, I0, MW, Mvar, MVA
0
Full numeric keypad
RS-232 and RS-485 ports

SR760 Feeder Management Relay

The Multilin SR760 Feeder Management Relay is an enhanced version of the Multilin SR750 relay, adding a four-shot recloser.
EPM7430D/EPM7450D
The Futura+ multifunction digital power-monitoring system offers the most extensive monitoring and analysis available. Surpassing all other meters in its class, this unit fulfills all your metering, data recording and power analysis needs. This is simply the best power monitoring and analysis solution ever. For a graphical view of all the meter can do, check out the Futura+ Communicator link. You will be very impressed.
Features
Multifunction Power Monitoring, Measuring
Every Parameter of Electrical Po we r
True RMS with 0.15% Accuracy
Extensive On-Board Storage for Virtually
Unlimited Data Trending
100 High-Speed Captured Waveform Events for
Voltage and Current Surges and Sags (All 6 Channels, 60 Cycles P er Channel Con stitute an Event)
Dual Digital Communication Ports: Modbus
RTU/ASCII, DNP 3.0, Modbus+ and Ethernet TCP/IP
Harmonic Distortion to the 31st Order
Multiple and Remote Displays
Extensive Digital and Analog I/O Capabilities
and Storage

Motor Manager II (MMII)

The Motor Manager 2 (MM2) combines control functions and compr ehensive motor protection in one package. This compact device provides sophisticated control and protective relaying at significant cost savings over the discrete devices normally found in a low voltage motor control center (MCC). One MM2 is required for every starter in the MCC. The contactor can be energized and de-energized using the MM2’s direct wired inputs, or via the serial port. A total of 6 fixed and 10 programmable switch inputs are available. A wide range of starter types may be controlled by the MM2 using two contactor outputs and two auxiliary
61
Power Management Control System
Appendix A — IED Descriptions
outputs. One analog input can be programmed by the user. A programmable undervoltage auto restart function is av ailable. Motor protection f eatures for the Error! No index entries found.most common causes of failure are provided to prevent costly shut downs and rewinds. These include overload, phase unbalance, locked rotor (stall), ground fault, undercur-rent and underpower. As well, a thermistor input can be provided to protect a hot winding. The relay also checks the contactor status at start and stop commands to indicate contactor failure. Alarms are provid-ed to warn of additional abnormal conditio ns.
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Power Management Control System
Appendix A – IED Descriptions
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63
Power Management Control System
Appendix B — Reference Documents
Appendix B lists documents that may be useful i n d e si gning and constructi ng a PMCS-based power manage m e nt system. Questions and problems should be add resse d t o the GE Resolution Cent e r, 1- 888- GE-RESOLV.
Document Number IED/Subject
GEH-6491 POWER LEADER Modbus C oncent rator User’s Guide GEH-6505 POWER LEADER Ethernet Gat eway U ser’s Guide GEH-5904 POWER LEADER Repeater User’s Guide GEH-5947 POWER LEADER Junction Box User’s Guide GEH-6273 MicroVersaTrip Plus and Mi croVersaTrip PM Trip Units for Type A KR Low-Voltage Power Circuit Breakers, Power
Break I and Power Break II I nsulated-Case Circui t Breakers, and R -Frame Molded-Case Circuit B reakers, and Low-
Voltage Power Circuit Breaker Conversion K its GEH-5892 POWER LEADER Meter User’s Guide GEH-6302 POWER LEADER Electronic P ower Met er U ser’s Guide DEH-027 POWER LEADER Modbus Monitor User’s Guide GEH-6435 Spectra RMS Electr onic Control Module GEK-100682 MDP Overcurrent Relay with commnet GEH-5933 MicroVersaTrip Plus and MicroVersaTrip PM Rat ing Plugs GEH-5934 MicroVersaTrip Plus and MicroVersaTrip PM Tri p Units in Spectra R MS Molded-Case Circui t Breakers GFK-0356 GE Fanuc Series 90™/30 Programmable Logic Controller I nst allation Manual GFK-0262 GE Fanuc Series 90™/70 Programmable Logic Controller I nst allation Manual GFK-0582 GE Fanuc Series 90™ Programmabl e Logic Controller Ser ial Communications User ’s Manual MRP70000-0007 Electronic Power Met er 3710 MRP70000-0004 Electronic Power Met er 3720 1665-0003-C5 Multilin Power Quality Meter (PQM) 1601-0067-C6 Multilin 239 Motor Protection Relay 16010013-BC Multilin 269+ Motor Management Relay 1601-0057-D3 Multilin SR469 Mot or Management Relay 1601-0071-E1 Multili n SR489 Generator Management Relay 1601-0017-E4 Multili n 565 Feeder Management Relay 1601-0048-DA Multilin 735 Feeder Relay 1601-0070-A3 Multilin SR745 Tr ansformer Management Relay 1601-0044-A8 Multilin SR750/ 760 Feeder Management Relay GEH-6508 Modbus Protocol Guide GEH-6509 PMCS DDE Interface G uide GEH-6510 PMCS Network and IED Configurator DDE Server Users Guide GEH-6511 PMCS Waveform Capture GEH-6512 PMCS Event Logger GEH-6513 PMCS Interface Toolki t GEH-6514 PMCS Read This Book Fir s t (installation gui de) GEH-6515 PMCS System Test Simul at or DEH-40035 GE 7700 Gateway User’s Guide 70000-0019 7300 ION Installation and Operation Manual
N/A EPM 5200P, 5300P, 5350P Digital Multifunction Power Moni tor Instruction Manual N/A EPM5000P Digital Multifunction Power Monitor Inst ruction Manual N/A EPM 9450Q and EPM 9650Q Advanced Power Monitor wit h P ower Quality Control Funct ions, Instruction Manual
Third-party IEDs Refer to the documentation that accompanied the device.
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Power Management Control System
Appendix B – Reference Documents
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Power Management Control System
Appendix C – Special Wiring Considerations
This section describes the connections required to wire the following PMCS IEDs into a Modbus RS-485 netwo rk :
GE Fanuc 90/30 and 90/70 PLC’s with
Communications C o processor modules.
GE Fanuc Micro 90 PLC
DB9 connections to the Connect Tech RS-485 card
DB9 connections to the POWER LEADER Ethernet
Gateway

90/30 and 90/70 PLCs

To wire the Communications Coprocessor module of a PLC 90/30 or PLC 90/70 to an RS-485 network, you will need two 100-inch lengths of Belden 9271 cable covered with sleeving and a ma l e DB- 25 c onnector.
The DB-25 connector should have the following jumper connections made inside the connector.
Pin 9 to Pin 13
Pin 21 to Pin 25
Pin 22 to Pin 23
Pin 10 to Pin 11
Connect the two cables to the DB-25 connector as follows:

Micro 90 PLC

NOTE: Micro 90 PLCs withfirmware revisions V3.10 and higher support 2 wire Modbus connections directly – the conversion from 4 wire to 2 wire is only needed with earlier versions.
To wire the communications port of a PLC Micro 90 to an RS-485 network, you will need two 100-inch lengths of Belden 9271 cable covered with sleeving and a B&B Electronics 485FWTW (or equivalent) two-to-four wire converter, a female DB-25 connector, and a male DB-15 connector.
The DB-15 connector should have the following jumper connections ma d e inside the connec tor:
Pin 6 to Pin 15
Pin 8 to Pin 14
Connect the two cables to the B&B 486FWTW as shown in Figures C-1 and C-2.
T
RS-232to RS-485
Converte r
120-ohm terminating re sisto r
RS-232to RS-485
Converter
2-wire cable
. . .
T
Last device
Conductor DB-25 Pin
Cable 1 White 21
Blue 9 Shield 1
Cable 2 White 25
Blue 13 Shield 1
Apply heat-shrink tape or jacket over the connector for protection.
At the end opposite the connector, strip about 3 inches off the outer jacket of each cable. Label one cable “RS-485 IN” and the other cable “RS- 485 OUT”.
HOST PC
(RS-232 port)
Series 90 Micro
(RTU p o rt)
4-wire cable
Figure C-1. RS-485 two-wire Modbus network.
PMCS Modbus Network 2-wire RS-485
Data A (-) Data B (+)
Shield
12 Vdc Power
Data A (-) Data B (+)
Signal Ground Frame G round
12 Vdc + 12 Vdc -
6 screw term ina ls
B&B 485FWTW
2/4 wire converter
3 RD A (-) 16 RD B (+) 2 TD A (-) 14 TD B (+)
7 Signal Ground 1 Frame Ground
12 Vdc + 12 Vdc -
25-pin male D-style conn ector
Micro 90 RTU Port 4-wire RS-422
10 RD A (-) 11 RD B (+) 12 SD A (-) 13 SD B (+)
7 Signal Ground 1 Sh ie ld
6 RTS A (-) 8 CTS B (+) 14 RTS B (+) 15 CTS A (-)
15-pin female D-style conn ector
Figure C-2. Modbus network and Series 90 Micro RTU
Port Wiring.
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Power Management Control System
Appendix C – Special Wiring Considerations
NOTE: The RTU port ground signal connection is not required but may be connected if needed. A one- to two-foot length should be enough for the four-wire RTU cable (with 25-pin female and 15-pin male D connectors) between the PLC and the 2/4 wire converter. Only Port 2 can be used for RTU communication on the 28-point Micro
90.

Connect Tech RS-485 card

For this connection, you’ll need a length of Belden 9271 cable covered with sleeving and a female DB-9 connector.
The DB-9 connector should have the following jumper connections ma d e inside the connec tor.
Pin 1 to Pin 2
Shield 5
Apply heat-shrink tape or jacket over the connector for protection.
At the end opposite the connector, strip about 3 inches off the outer jacket of the cable.
Pin 3 to Pin 4
Pin 6 to Pin 7
Pin 8 to Pin 9
Connect the cable to the DB-9 connector as follows:
Conductor DB-9 Pin
Cable 1 W hi t e 1
Blue 3 Shield Metal shell
Apply heat-shrink tape or jacket over the connector for protection.
At the end opposite the connector, strip about 3 inches off the outer jacket of the cable.

Ethernet Gateway

The Ethernet Gateway RS-485 connection requires one 48-inch length of Belden 9271 cable covered with sleeving and a male DB-9 connector.
Connect one end of the cable to the DB-9 connector as follows:
Conductor DB-9 Pin
White 1 Blue 2
67
Power Management Control System
Notes
68
g
General Electric Company 41 Woodford Ave., Plainville, CT 06062
GEH-6502 R045 01/02 © 2000 - 2002 General Electric Company
GE Industrial Systems
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