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Original Instructions 4-2013 A044E523 (Issue 1)
Table of Contents
1. INTRODUCTION............................................................................................................................ 1
1.1 Overview ................................................................................................................................. 1
1.2 About This Manual.................................................................................................................. 2
1.3 Application Manuals................................................................................................................ 3
1.4 Safety...................................................................................................................................... 3
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3.4.3 Bridge......................................................................................................................... 24
3.4.4 Routers....................................................................................................................... 25
3.4.5 Gateways ................................................................................................................... 25
3.5 Web Servers ......................................................................................................................... 26
5. MEDIA CONSIDERATIONS......................................................................................................... 35
5.1 Overview ............................................................................................................................... 35
5.2 Cable Concepts .................................................................................................................... 35
5.2.1 Attenuation ................................................................................................................. 35
5.2.2 Characteristic Impedance and Network Termination ................................................. 35
5.2.3 Electromagnetic Interference ..................................................................................... 36
5.2.4 Crosstalk .................................................................................................................... 36
5.2.5 Shielding .................................................................................................................... 37
5.2.6 Insulating Jacket - Plenum vs. PVC .......................................................................... 38
5.3 Cable Types ......................................................................................................................... 38
5.3.1 Twisted Pair Cable..................................................................................................... 39
5.3.2 Fiber-Optic Cable ....................................................................................................... 40
5.3.3 Coaxial Cable............................................................................................................. 40
5.4 Twisted Pair Cable Standards .............................................................................................. 41
5.4.1 NEMA Level IV Cable ................................................................................................ 41
5.5 Physical Layer Protocols ..................................................................................................... 41
5.5.1 Ethernet...................................................................................................................... 41
5.5.2 Modbus over Serial Line ............................................................................................ 42
5.5.3 PCCNet ...................................................................................................................... 43
5.5.4 LonWorks ................................................................................................................... 43
5.5.5 Wireless Media........................................................................................................... 44
6. PROTOCOLS............................................................................................................................... 47
6.1 Overview ............................................................................................................................... 47
6.2 Protocols ............................................................................................................................... 47
6.2.1 Proprietary vs. Open Protocols .................................................................................. 47
6.3 The OSI Reference Model .................................................................................................... 48
6.3.1 Layer 1 - Physical Layer ............................................................................................ 48
6.3.2 Layer 2 - Data Link Layer .......................................................................................... 50
6.3.3 Layer 3 - The Network Layer ..................................................................................... 52
6.3.4 Layer 4 - Transport Layer .......................................................................................... 55
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7. MONITORING SYSTEMS............................................................................................................ 65
7.1 Overview ............................................................................................................................... 65
7.2 Purpose of Monitoring........................................................................................................... 65
7.2.1 System Reliability....................................................................................................... 65
7.2.2 Operating Cost ........................................................................................................... 65
7.2.3 Agency Requirements................................................................................................ 66
7.3 Monitoring System Functions................................................................................................ 66
7.3.1 Status Display ............................................................................................................ 66
7.3.2 Alarm Notification ....................................................................................................... 69
7.3.3 Data Logging.............................................................................................................. 69
7.3.4 Reporting.................................................................................................................... 72
7.4 Monitoring System Architecture ............................................................................................ 72
7.4.1 SCADA Systems ........................................................................................................ 73
7.5 Web-based Monitoring Systems ........................................................................................... 75
7.5.1 Web Server Location ................................................................................................. 77
7.6 Which Monitoring System to Choose.................................................................................... 78
9. APPENDIX ................................................................................................................................... 85
9.1 Glossary................................................................................................................................ 85
9.2 Acronyms .............................................................................................................................. 93
9.3 Codes and Standards ........................................................................................................... 96
9.3.1 Related Product Standards........................................................................................ 96
9.3.2 Modification of Products............................................................................................. 97
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WARRANTY
This manual is published solely for information purposes and should not be considered all inclusive. If
further information is required, consult Cummins Power Generation. Sale of product shown or described in
this literature is subject to terms and conditions outlined in appropriate Cummins Power Generation selling
policies or other contractual agreement between the parties. This literature is not intended to and does not
enlarge or add to any such contract. The sole source governing the rights and remedies of any purchaser of
this equipment is the contract between the purchaser and Cummins Power Generation.
NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A
PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF
DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION,
RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN. Each customer is responsible for the
design and functioning of its building systems. We cannot ensure that the specifications of Cummins Power
Generation products are the proper and sufficient ones for your purposes. You must satisfy yourself on that
point.
In no event will Cummins Power Generation be responsible to the purchaser or user in contract, in tort
(including negligence), strict liability or otherwise for any special, indirect, incidental or consequential
damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power
system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims
against the purchaser or user by its customers resulting from the use of the information, recommendations
and descriptions contained herein.
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vi A044E523 (Issue 1)
1 Introduction
1.1 Overview
The purpose of this Application Manual is to educate engineers, system integrators, distributors,
and interested users in the fundamentals of networks, as they apply and are used in on-site
power generation systems.
Communication networks have long been used to make equipment and processes operate more
reliably and efficiently in the following ways:
• Networks improve system reliability by communicating fault or potential fault conditions to
equipment or personnel that can take appropriate action to prevent failures or equipment
damage.
• Networks improve serviceability of a system as technicians are able to assess a system’s
service requirements remotely and in some cases allow for download of software upgrades
over the internet.
• Networks minimize operating costs by making service more efficient and simplifying status
indication and reporting requirements.
• Networks minimize installation costs by reducing point to point wiring and the associated
wiring errors.
• Networks enable more efficient operation of a system as operating and performance
information enables a system controller to cycle equipment on or off and make other
adjustments of operating parameters.
• Networks allow building management systems to monitor and control equipment. This
includes heating and cooling, lighting, transportation and security systems as well as power
generation and distribution equipment.
• Data provided over a network is often used for trend analysis which can optimize system
performance over time or be used to diagnose problems.
Networks will play an expanded role in power generation, distribution and transmission systems
moving forward. Demand for power is growing in excess of existing generation capacity at the
same time tolerance for interruptions in our power supply is decreasing. Developing additional
centralized generation capacity is capital intensive and fraught with political difficulties as fuel
sources are perceived as non-renewable, harmful to the environment and pose health and
safety risks. This results in a demand for distributed rather than centralized power generation
sources and for improvements to power transmission systems in terms of supplying energy
needs more efficiently and more effective fault isolation and fault tolerance systems.
As power generation systems migrate from centralized to distributed generation and control, the
communications infrastructure will need to become more comprehensive and standardized so
that equipment from multiple suppliers will be able to communicate with each other seamlessly.
Seamless communication is the enabling technology that allows the potential advantages of
distributed power generation to be realized. Examples of this include
• Switching loads off of the grid when there is a danger of a utility transformer becoming
overloaded or to do maintenance on utility distribution equipment
• Exporting power to the grid from distributed sources to serve loads that have been
interrupted due to a fault in the distribution system.
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• Supplementing alternative energy sources with diesel gensets to mitigate the intermittent
nature of the alternative source
• Implementing load demand schemes across multiple distributed sources in order to use the
available capacity most efficiently.
Even equipment that is not connected to a grid will be expected to communicate with other
equipment for applications ranging from simple remote alarm notification to full monitoring
control and analysis. Networking capability is becoming an enabling technology for power
generation equipment across the entire range of power generation applications.
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1.4 Safety
Safety should be a primary concern of the facility design engineer. Safety involves two aspects:
safe operation of the generator set itself (and its accessories) and reliable operation of the
system. Reliable operation of the system is related to safety because equipment affecting life
and health is often dependent on the generator set – such as hospital life-support systems,
emergency egress lighting, building ventilators, elevators, fire pumps, security and
communications.
Refer to the Codes and Standards section for information on applicable electrical and fire codes
around the world. Standards, and the codes that reference them, are periodically updated,
requiring continual review. Compliance with all applicable codes is the responsibility of the
facility design engineer. For example, some areas may require a certificate-of-need, zoning
permit, building permit or other site-specific certificate. Be sure to check with all local
governmental authorities early in the planning process.
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NOTE: While the information in this and related manuals is intended to be accurate
and useful, there is no substitute for the judgment of a skilled, experienced
facility design professional. Each end user must determine whether the
selected generator set and emergency/standby system is proper for the
application.
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2 Networking Basics
2.1 Overview
A network can be defined as a collection of devices or “nodes” that communicate with one
another over a common medium (i.e. wire, fiber, wireless) where information is exchanged via
sets of rules known as protocols. In this chapter we will define some of the key terms and
concepts associated with networks and discuss how networks have evolved historically.
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Even a simple generator set application could include some pretty complicated wiring, as
indicated in Figure 2, because every wire would have a specific purpose and would need to be
connected in exactly the correct location.
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2.3.1 Protocols
A protocol can be defined as a set of rules used mutually by two or more devices or software
applications to communicate. Protocols specify all of the characteristics of a communication
network from the physical and electrical qualities to the languages used to communicate.
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2.3.2 Topology
Topology refers to the physical shape and interconnection scheme of the network. The three
most common topologies used in control networks are known as "bus", "ring", and "star". A bus
topology is one in which all of the devices are connected in a line. A ring topolgy is similar to a
bus topology except the devices on the ends are connected forming a closed loop. A star
topology is one in which one device is in the center and connects to all of the other devices like
the hub and spokes of a wheel.
2.3.3 Bus
The terms media, bus, and channel are often used interchangeably to describe the physical
carrier of the communication. While the terms are related they do have separate meanings.
A bus refers to the "backbone" of a communication channel. When a bus topology is used all of
the nodes on the network are physically connected to the bus.
2.3.4 Channel
A channel refers to an uninterrupted physical communication path. Most PowerCommand
networks consist of a single channel. More sophisticated networks will have multiple channels. A
single channel consists of only one protocol and one type of media. Devices such as routers
and gateways can combine separate channels consisting of different protocols and media into a
single network. Routers and gateways will be discussed in detail in Chapter 3.
Figure 5 illustrates the concept of a channel and a bus. Each of the routers separate the
network into two channels: a Lon channel and an Ethernet channel. Each of the channels is
connected in a bus topology with each device on the channel connected to a common pair of
wires. This pair of wires is referred to as the bus.
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2.3.5 Media
Media is the generic term for the physical carrier of the signal, whether it is copper wire, fiber
optic cable or, as in the case of wireless communication, air.
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2.3.6 Node
The term "node" is a generic term referring to any device connected to a network. A node could
be a generator set control, an annunciator, a router or a web server, or any device on the
network.
2.3.7 Bandwidth
Bandwidth refers to the speed of communication over the network. It is the amount of data that
can be transmitted in a fixed amount of time, usually expressed as bits per second (bps or
bit/s). The term bandwidth is also used to express the finite amount of time in which certain
communication may occur, so phrases like “that’s not an efficient use of bandwidth” refers not
only to the speed of the propagation of the data but also to the total amount of time that a
transmitting device uses to access the communication channel.
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2.5.1 RS-232
As communication equipment became more widely used, there was a need to develop a
standard communication protocol so that equipment from several different manufacturers could
communicate with each other. The standard protocol was developed by the Electronic Industries
Association (EIA) and was known as RS-232. The RS-232 standard defines communication
between two specific types of equipment known as Data Terminal Equipment (DTE, typically a
PC) and Data Communications Equipment (DCE, typically a modem) over a distance of no
more than 50 feet (15 meters). RS-232 also specified the pin designations on the 9- and 25-pin
connectors that were most common at the time. RS-232 defines separate transmit and receive
wiring paths with the transmit pin on one device physically connected to the receive pin on the
other device. This means that both devices can transmit at the same time. This is known as full-
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duplex communication (see Figure 7). Although it was designed for a very narrow scope of
applications (communication between only two devices no more than 50 feet (15 meters) apart)
RS-232 is still commonly used in those applications today due to its simplicity and relatively low
cost to develop and deploy. Cummins Power Generation’s proprietary Mon protocol, which is
used by the InPower service tool to connect to controls, is built on the RS-232 physical layer.
2.5.2 RS-485
RS-485 was developed as the standard for connecting more than two devices on a network
over longer distances. Unlike RS-232, which has separate circuits for transmitting and receiving
signals, RS-485 specifies a single circuit for both transmitting and receiving signals, known as a
transceiver. The RS-485 transceiver is designed in such a way that multiple transceivers can be
connected to the network without affecting the one transceiver that is transmitting a signal (see
Figure 8). RS-485 was designed so that signals can travel long distances without being
attenuated by resistance and inductance in the wires and have a high level of noise immunity.
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Cummins Power Generation’s PCCNet protocol, used to communicate between a generator set
and its accessories, such as human machine interfaces (HMIs) and annunciators, is built on the
RS-485 physical layer. As the RS-485 standard defines only the physical layer of
communication, it defines distance and bandwidth. Addressing and controlling access to the
communication channel is outside of the scope of the RS-485 standard and is defined by higher
level protocols.
2.6 Addressing
Each device on a network must have a unique identifier often known as an address. Many
protocols will define both a logical and a physical address. The logical address is assigned
when the network is commissioned; if the same device is used in a different network in the
future, it will likely be assigned a different logical address. Also, if a device fails and needs to be
replaced, the new device will most likely be assigned the same logical address as the device
that it replaced.
Some protocols, such as Ethernet and LonWorks, will also specify a physical address. The
physical address is assigned by a standards body, is unique in the world, and is permanently
assigned to a specific device.
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2.8 Determinism
When networks are used to transmit time critical data for controllers, there is a need for the
communication to be deterministic, meaning that the amount of time it takes for a certain
message to travel between devices must be predetermined and consistent. In this case,
protocols will include some priority arbitration scheme so that critical messages will pre-empt
noncritical messages and devices transmitting these messages will get priority in accessing the
bus.
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3. A CAN network for communicating between the genset controller and the Engine Control
Module (ECM). Can is a commonly used protocol in the automotive industry used to
communicate between the engines and other control systems in a vehicle. It is the standard
protocol used by Cummins ECM's in all kinds of applications and in a genset is used only
for communicating between the genset control and the ECM.
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3 Network Devices
3.1 Overview
In this chapter we will identify the types of devices that are commonly found in a power
generation system network. We will refer to Cummins Power Generation’s products as
examples.
We will discuss five types of devices: I/O devices, intelligent controllers, network interface
cards, network management devices (hubs, switches, routers, gateways), and web servers.
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A common method for implementing a digital output is to use a form C contact (see Figure
12). A form C contact consists of one normally open and one normally closed contact and a
common line between the two contacts, which ensures that one contact is always open and one
is always closed to the common line and activating the output will change the state of both
contacts. The digital outputs on Cummins CCM, DIM, and Aux 101 are form C contacts.
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There are also devices on the market that create a current which is proportional to a measured
parameter. A common standard is 4 – 20 mA devices. To monitor this with a CCM, the current
is passed through a known resistance (off of the CCM board) and the CCM can read the voltage
across the resistor.
To make use of the values created by the A/D circuit, it is necessary to know how the
parameters are scaled. Scaling will depend on the physical properties of the sensing circuit and
the resolution of the A/D converter. For example, a temperature sensing circuit will convert
temperature to voltage depending on the resistance/temperature characteristic of the sender
and the current source. The A/D converter will convert that voltage to a number of “counts”
based on its resolution. For instance, a 10 bit A/D converter will convert the measured voltage to
a number of counts between 0 and 1024 (2^10). When the conversions between the measured
parameter and analog voltage, and between analog voltage and A/D counts are known, the
conversion between the measured parameter and counts can be calculated.
In many cases, the I/O device, or the control that gathers input from the I/O device, will make
this calculation or there will be a tool to make this calculation. In other cases, it will be easier to
establish the conversion through a test if it is known that the relationship between the measured
parameter and the analog voltage is linear. Simply reading the A/D output for 2 known inputs
will allow a simple calculation of the conversion factor. For example, consider a temperature
sender. Through test it is determined that at a temperature of 197 °F the sender had a voltage
of 3.23V and at 172 °F the voltage was 2.9 V. With these 2 points we can determine the sender
gain and the offset for the sender. The gain defines how much the voltage changes for each
degree of temperature change. It is simply the ratio of the difference in temperature to the
difference in voltage. In this example it is (197-172)/(3.23-2.92) = 80.65 °F/V. This means that
for every 80.65 degrees that the temperature changes, the voltage will change by 1 volt. The
fact that the gain turned out to be a positive number indicates that as the temperature increases
the voltage will increase. Some types of sensors have a negative gain, meaning that as the
sensed parameter increases the corresponding voltage decreases.
Some senders do not have an output of 0 volts when the parameter being sensed is at 0. In
those cases we need to calculate an offset to fully define the sender. To continue the example
above, we will calculate the offset for that sender, which is the temperature that would
correspond to 0 volts. We can calculate this using the sender gain and one point. We'll use the
2.92V, 172 degrees point. The equation is 172 - 2.92*80.65 = -63.5. This means that 0 volts
would correspond to a temperature of -63.5 degrees. A plot of the linear relationship between
temperature and voltage is shown in Figure 13. Note that different analog devices have
different calibration tools and methods. This is just one example.
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3.4.1 Hub/Repeater
Hubs and repeaters are simple devices that repeat all of the network signals to all network
devices to which they are connected. They do not process data or make any type of decision
regarding where to send the data.
A repeater has two ports. It connects two segments of a network. Since they are able to amplify
a weak signal, repeaters are able to extend a network over large physical distances.
A hub has multiple ports and allows devices to attach to a network in the star configuration.
(See Section 4.2 on page 29 for discussion on network topology.) A hub receives data and
broadcasts the data to all of its ports.
Hubs and repeaters are becoming less common as they are not able to meet demands for
faster networks with more devices. More often than not, they are replaced by Ethernet switches.
3.4.2 Switch
A switch is similar to a hub except instead of broadcasting all the messages it sees, it checks to
see that there are no errors in the message packet and if there are no errors, it will transmit the
message only to its intended recipient.
By sending only “good” messages to their intended recipient, switches increase the speed of the
network by eliminating a lot of unnecessary and erroneous traffic. Switches can also improve
network speed by eliminating collisions.
Ethernet switches divide a network into segments called “collision domains”. A collision domain
is defined as a set of network devices whose packets can collide with each other. As discussed
in Chapter 2, if two devices on a network try to “talk” at the same time there is a collision. When
a collision occurs, all the data is lost and each device will delay its message before attempting
to transmit again.
Because a switch manages traffic between ports, there will be no collisions between devices on
separate ports. Only devices that are connected to the same port of a switch can experience
collisions. Devices connected to the same port on a switch are said to be in the same collision
domain. To completely eliminate the possibility of collisions, only a single device is connected to
each port of a switch. There is only one single device in each collision domain.
To maximize speed of network communication, full duplex switching is employed. Full duplex
communication allows devices to both transmit and receive messages at the same time. This is
accomplished by each device having separate transmit and receive lines. By using full duplex
communication with only one device on each collision domain the speed of communication is
optimized. It is limited only by the characteristics of the transceiver and the media.
3.4.3 Bridge
A bridge is similar to a switch except that a bridge has only two ports where a switch may have
many ports. A bridge can connect two network segments separated by large distances or two
segments that are communicating over different types of physical media.
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3.4.4 Routers
Routers are similar to switches in that they both manage network traffic. The difference is that
switches direct traffic within a local network; whereas, routers direct traffic between
networks. Where a switch communicates between network segments that are physically
connected to that switch, routers can connect two devices that are physically separated by great
distances with multiple routers in between them. Routers operate based on a device’s logical
address rather than physical location. To illustrate, one can connect his/her laptop to their
internet service provider’s server from their home, their office, an airport or their favorite coffee
shop. The physical location does not matter; it is the IP (Internet Protocol) address, the logical
address, that matters.
Routers enable networks that use different media, access, and addressing protocols to
communicate with each other. (They can translate between different Physical, Data Link, and
Network Layer protocols, and layers 1, 2 and 3 of the OSI model. The OSI model will be
discussed further in Chapter 6.) They do not translate between higher level languages
(Application Layer), such as LonWorks and Modbus.
A common example of this is in a campus application where generators, transfer switches, and
switchgear are all located in an equipment room and are to be monitored in a control room a
great distance away. There is an Ethernet connection over fiber optic cable between the two
rooms. The equipment communicates via LonWorks over twisted pair wire. In each of the two
rooms there would be a router with one channel connected to the twisted pair wire and the
second channel connected to the fiber. The router does not translate the high level language
(LonWorks), it just manages the transmission of data from the twisted pair network, over the
fiber optic cable, and back to the twisted pair network at the other end. See Figure 15.
3.4.5 Gateways
A gateway is a device that enables two network segments of different protocols to communicate
with each other. A gateway manages all layers of the OSI protocol stack from the physical
media to the high level language. Cummins Power Generation’s ModLon Gateway (see Figure
16), which converts LonWorks to Modbus data for Cummins products, is a good example of a
gateway. It should be noted that gateways can slow down communication and in some cases
can compromise reliability as they introduce single points of failure into the system.
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4 Network Characteristics
4.1 Overview
This chapter defines physical network characteristics, topology, bandwidth, and distance. It
describes the interaction between these characteristics and provides a baseline for comparison
of various media and protocols.
Selection of topology, bandwidth, and distance impose tradeoffs on a system. Typically,
bandwidth and distance conflict with each other. Increasing the physical distance between
devices decreases the maximum speed of data transmission. Topology choices will affect the
other capabilities as well, with the simplest topology allowing for the greatest distance and
bandwidth, while more complex topologies will impose limitations.
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4.3 Bandwidth
Bandwidth is the amount of data that can be transmitted in a fixed amount of time. It is usually
expressed in bits per second. It is a function of the physical properties of the media and the
method used to transmit data. (These are characteristics of Physical Layer protocols as defined
by the OSI model. This is discussed in Chapter 6.)
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The term bandwidth is often used interchangeably with network speed, but bandwidth is actually
a measure of network capacity. It is a measure of how fast data can travel through some media
rather than how fast data is actually travelling. A common analogy is to think of data flowing
through a pipe. Bandwidth is analogous to the size of the pipe. Increasing the bandwidth allows
more data to flow during some period of time but does not necessarily cause more data to flow.
Along with bandwidth, the other key factor that affects the speed of a network is latency or
delay. The term latency is defined as the amount of time it takes a packet of information to
travel from its source to its destination. Topology is the key factor affecting latency in control
networks as it takes a finite amount of time for routers and switches to process and forward
data. In Wide Area Networks, distance can significantly affect latency, particularly with cellular or
satellite communication as data travels at a finite rate. Latency is not always predictable in Wide
Area Networks as routers may not always send data to its destination over the same path.
4.5 Distance
Like bandwidth, a network’s maximum distance is determined by the media and by the
properties and methods of the device that is transmitting the data. Resistance in a cable will
attenuate signals that are transmitted over it. As a cable gets longer, resistance, and therefore
attenuation, increase until the signal is attenuated so much that the receiving device is not able
to interpret it.
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Properties of the transmitting device will also affect the maximum network distance. For
example, RS-232 and RS-485 networks can both communicate over twisted pair wires, but RS-
485 devices communicate in a manner that minimizes the effects of attenuation (and minimizes
the effects of interference) so that it can communicate over a much longer distance.
With some protocols, such as CAN and RS-485, the maximum speed and maximum distance
have a trade off. This tradeoff is caused by the capacitance of the cable. Capacitance delays
voltage transitions between states. If transmission of a second bit begins before the first bit
reaches its intended state, communication will fail. Data cannot be transmitted faster than it can
be propagated so a long distance may limit the maximum speed.
Network topology can also affect the maximum distance. For instance, with LonWorks, a bus
topology which is terminated (grounded through a resistance) at both ends has a higher
maximum distance than a LonWorks network with any other topology. This is due to the
terminated bus allowing signals to have better immunity to interference.
Some protocols, such as Ethernet and LonWorks, have routers or repeaters available which
allow extending the physical length of the network. These devices will re-transmit the signals
that they receive so distance limitations imposed by the media will apply to each segment of the
network connected to the device rather than to the entire network. LonWorks has a limit to the
number of routers that can exist on a single network, so that sets the maximum total length of
the network. Ethernet does not have any restriction to the number of devices on the entire
network so there is no practical limit to the distance of an Ethernet network.
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5 Media Considerations
5.1 Overview
This chapter discusses media over which communication signals travel. General application
considerations such as termination, grounding, and shielding are covered, as well as commonly
used media and how and where they are used. This chapter will focus on wired media because
the vast majority of industrial networks are wired. Some basic wireless concepts will be
discussed briefly at the end of the chapter.
5.2.1 Attenuation
Attenuation is a measure of the decrease in signal strength along the length of the media due to
resistance in the media and outside interference. Attenuation is typically expressed in decibels
(dB) as the ratio of output to input signal level and is the primary reason that network standards
specify maximum cable lengths.
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With long lengths of cable the electrical characteristics of the cable can result in transmission
line effects, such as standing waves and signal reflections, which could distort the signal. A
cable is generally considered electrically "long" when the length of cable exceeds 1/4
wavelength of the signal. Wavelength can be approximated by dividing the speed of light by the
frequency of the signal. Therefore as cable length and frequency of the signal increase the
transmission effects become more prominent. Transmission line effects can be minimized by
placing a terminating circuit in the network. For most networks using twisted pair wire, the
terminating circuit is simply a resistor that matches the characteristic impedance of the cable
placed at each end of the network. This is known as terminating the network (see Figure 20).
NOTE: LonWorks network termination requirements are more complex than this and
are discussed in the LonWorks Section 5.5.4.
In some cases, an AC termination circuit is used consisting of a resistor-capacitor (RC) network
rather than a terminating resistor at the end of the network. In general, the capacitors charge
and discharge as the bus changes state effectively switching terminating resistors into the
network to minimize reflections as needed. An AC termination circuit is not as robust as a
terminating resistor from a signal quality standpoint but has the advantage that it can be located
throughout the network rather than at the end. This allows manufacturers to integrate a
terminator on to a communication device which eliminates the need for the network installer to
terminate the network.
5.2.4 Crosstalk
Crosstalk is interference from adjacent cables that are close together and running side by side.
It results from signals of one cable being magnetically coupled to another cable and can be a
concern when there are multiple pairs of cable within a single insulating jacket. Conductors are
twisted about each other in twisted pair cable to counter this problem. As the cables twist about
each other, the polarity of the signal reverses, nullifying the crosstalk to some extent but not
eliminating it fully. The measurement for crosstalk is called NEXT (Near End Crosstalk) and is
expressed in dB as a measure of the signal loss in coupling from one pair to another. Cable
specifications specify a minimum level of crosstalk coupling loss for various frequencies.
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5.2.5 Shielding
Shielded cables are used to combat EMI. The shield can reflect EMI energy but its primary
purpose is to conduct EMI energy to ground. In order for the shield to work, it must be grounded
at only one point. Failure to make a good ground connection will limit the ability of the cable to
shield the conductors from EMI. Grounding the shield at more than one point will allow EMI
energy to circulate on the shield and potentially allow coupling energy onto the conductors. Note
that grounding here refers to the control ground rather than an equipment ground. Many
controls that use shielded cable for communication have a terminal for connecting the shield.
A shield will affect the characteristic impedance of the cable so it is not appropriate to replace
unshielded cable with shielded cable without considering the network termination circuits.
There are two types of shielding typically used for cables: foil (Figure 21) and braid (Figure 22).
Foil shielding uses a thin layer of aluminum, typically attached to a carrier, such as polyester, to
add strength and ruggedness. A braid is a woven mesh of bare or tinned copper wires. Because
copper has higher conductivity than aluminum and the braid has more bulk for conducting noise,
the braid is more effective as a shield but it adds size and cost to the cable. A braid is also more
durable than foil in applications where the cable will be flexed.
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FIGURE 24. TYPICAL OFFICE LAN UTP CABLE WITH RJ45 CONNECTOR
In relatively high EMI environments, such as environments with motors and drives, it is often
necessary to use shielded twisted pair (STP) cable. The shield gives the cable better immunity
to EMI but is more expensive and more difficult to work with than UTP, and if the shield is not
grounded properly the shielding effects are negated.
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Thick coaxial cable or “Thicknet” has an extra protective plastic cover that helps keep moisture
away from the center conductor. Thicknet cable does not bend easily and is more difficult to
install than Thinnet cable. It has a maximum segment length of 1640 feet (500 meters).
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media, 10 Mbps in this example. The “T” refers to the type of cable, twisted pair in this
case. The word “Base” indicates that the transmission is baseband rather than
broadband. Baseband communication uses the complete bandwidth of the cable system, so
only one signal is ever found on the cable at any time. Baseband communication is most
commonly used in LANs and control networks. Broadband transmission, by contrast, is analog
rather than digital and supports multiple different signals using the same cable simultaneously,
each signal operating at different frequencies. Broadband communication is not used within
control networks and will not be discussed further in this document.
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5.5.3 PCCNet
PCCNet is a proprietary Cummins Power Generation protocol which uses an RS-485 physical
layer. Cummins specifies Belden 9729 shielded twisted pair or equivalent cable for PCCNet
networks. CPG controls include a terminating resistor that matches the characteristic impedance
of the 9729 cable so PCCNet networks do not require an external terminator. Maximum total
network length is 4000 feet (1219 meters). As with all networks using shielded cable, it is
required to ground the shield at one point in the network. Connectors on CPG controls that are
used for PCCNet communication include a terminal for connecting the shield to ground.
5.5.4 LonWorks
CPG’s LonWorks networks use stranded, unshielded, twisted pair cable. The following cables
are qualified for use with FTT-10 networks:
• NEMA Level IV cable (Cummins P/N 334-1350 [PVC] or 334-1351 [Plenum])
• EIA/TIA Category 5 (CAT5) (stranded only)
The maximum network length depends on which cable and topology are used. Table 3 lists the
maximum network length for each cable when a “free topology” is used. In this instance “free
topology” can be defined as any topology other than a bus. Table 4 lists maximum network
length when a bus topology is used. A LonWorks bus network may use stubs up to 10 feet (3
meters) long.
CPG LonWorks network segments require termination for proper data transmission
performance. Free topology and bus topology networks differ in their termination requirements.
Free topology segments only require one terminator per segment. This terminator can be placed
anywhere in the segment but is recommended to be placed near the middle of the segment. All
CPG Lonworks cards (cards for 3100, 3201, and 2100 genset controls, OTPC, BTPC, OHPC,
and CHPC ATS controls), Control Communications Modules (CCM), Digital I/O Modules (DIM)
and Lonworks Annunciators have an on-board free topology terminator. It is recommended that
this be used on a free topology segment. These boards have a terminator switch. One switch on
the network device must be in the terminate position and all others left unterminated. The
ModLon gateway also has a terminator switch. The ModLon terminator is configured for a bus
topology.
To utilize the maximum bus length allowed by a bus topology network, the network must be
terminated at both ends of the bus. Cummins Power Generation offers a terminator for this
purpose (p/n 0300-5729).
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5.5.5.1 Wi-Fi
IEEE 802.11 defines the media access and physical layers for wireless LANs. It is the dominant
standard for wireless internet access. Wi-Fi is the commonly used term for networks that meet
this standard.
Power generation networks can be connected to a wireless LAN using a wireless
adapter. There are devices available that will connect a wired Ethernet network (communicating
using Modbus/TCP) or a serial network (communicating using Modbus RTU over RS-485) to a
wireless LAN so that the network can be monitored over the internet.
5.5.5.2 Bluetooth
IEEE 802.15 defines the media access and physical layers for wireless personal area networks
(WPAN), defined as ad hoc networks transmitting up to 33 feet (10 meters). The technology
was originally developed by an organization called the Bluetooth Special Interest
Group. Bluetooth is the common term for this technology.
5.5.5.4 Cellular
Cellular technology has been used to connect power generation equipment with remote
monitoring stations for many years. Most major generator manufacturers offer a cellular
monitoring product. The monitor communicates with the genset control using either discrete
hardwired I/O signals or a serial link and sends data over a cellular network to a monitoring
center.
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There are two cellular communication technologies: Global System for Mobile communications
(GSM) and Code Division Multiple Access (CDMA). The appropriate technology to use depends
almost entirely on location. CDMA is the dominant technology in the US, GSM is dominant
everywhere else. There are some exceptions to this, as some U.S. carriers support GSM
networks. Work with the cellular service provider at the location of the power system to
determine the appropriate cellular technology.
Cummins Power Generation’s PowerCommand 500 and 550 Remote Monitoring Systems are
available with either CDMA or GSM capabilities. CDMA or GSM must be specified when
ordering the product.
5.5.5.5 Satellite
Satellite communication is often used when high cost equipment is in a mobile environment
such as rental or used in remote environments where cell phone service is not
available. Because satellites communicate over RF signals, the antenna must have “line of
sight” visibility to the sky. Satellite service providers charge substantially higher rates than
cellular providers but they offer true global coverage.
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6 Protocols
6.1 Overview
This chapter defines and describes protocols using the Open Systems Interconnection (OSI)
model as a framework for the discussion. Protocols used by Cummins Power Generation’s
(CPG) products as well other commonly used protocols are defined in the context of the OSI
model and how and where they are typically used is discussed. For protocols that are not used
by standard CPG products, a description of how CPG products may interact with equipment
using that protocol is included.
6.2 Protocols
A protocol can be defined as a set of rules used mutually by two or more devices or software
applications to communicate. Protocols specify all of the characteristics of a communication
network from the physical and electrical qualities to the languages used to communicate.
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Physical Medium: Specifies what carries the signal, such as copper wire, fiber optic cable,
radio waves, etc.
Signal Characteristics: Describes how the signal works electrically. Defines what constitutes a
"1" or a "0", whether they are voltage levels, pulses, or rising or falling edges between pulses.
Bit Encoding: Defines how data bits get encoded for transmission. Specifies parameters such
as whether the most or least significant bit is transmitted first and whether the bit stream needs
to be modified to keep the transmitting and receiving devices in sync with each other. For
example if there were a long string of consecutive zeros, there would be no transitions of the
signal and the receiving device could lose track of how many bits have been received.
Bit Rate (Bandwidth): Defines how many bits per second the media will accommodate.
Specifies "the size of the pipe".
Distance Limit: Defines how far two devices can be from each other. This is the wire length for
wired protocols and the physical distance between devices for wireless protocols.
Duplex: Defines whether the nodes can both transmit and receive simultaneously (full duplex)
or if the can only do one at a time (half duplex).
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Distance Limit: For copper, 328 feet (100 meters) is the limit due to signal degradation over
that distance. The beauty of Ethernet though is that this distance can be extended almost
indefinitely with switches and routers. These are intelligent devices that clean up the signal and
forward the message on to its destination.
Duplex: Ethernet originally ran half duplex and used hubs to extend the network. The network
could only be extended so far before the “collision domain” limit would be exceeded. Today’s
Ethernet is full duplex and uses switches to extend the network. There is no collision domain
issue since the switches manage the full duplex traffic flow, so network size/distance is
practically unlimited.
Other Ethernet Media Examples
Fiber Optic Cable: There are several Ethernet standards for fiber optic cable. One of the most
common is Ethernet 100 Base-FX which is capable of internode distances of over 1 mile.
Radio Frequency: IEEE 802.11g is the most common wireless (Wi-Fi) standard. IEEE 802.11g
networks can run at 54 Mbits/sec covering a radius of at least 65 feet (20 meters).
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NOTE: This does not necessarily cover the case of intentional (hacking) corruption,
only signal corruption due to electrical interference, noise, etc.
Application layers higher in the stack are concerned with making sure there has not been
intentional corruption. For example, Ethernet networks use a 32 bit data integrity scheme called
a Cyclic Redundancy Check (CRC). This is an algorithm that calculates a number based on all
the other bits in the frame. This number gets calculated by the sender and sent along with the
frame. The receiver then also calculates the CRC and compares its result with the CRC
received from the sender. If they match, the frame is good. If not, it must be thrown away and
resent.
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In simple control networks using protocols such as Modbus, LonWorks, or PCCNet, the logical
address can be as simple as a one digit number. A device is assigned a logical address when it
is commissioned and that address typically does not change throughout the life of the network.
If a device fails and needs to be replaced, the new device will typically be assigned the same
logical address as the device it replaced. All the devices on the network will use logical
addresses to communicate with each other.
In more extensive networks, such as LANs (Local Area Networks) or WANs (Wide Area
Networks), devices will have more extensive logical addresses that will change in some
cases. For example, Internet Protocol (IP) defines a 32 bit logical address for devices known as
the IP address. In WANs that span multiple sub-networks and routers, the routers will use the
information encoded in the IP address to identify a path or route between the sending and
receiving devices. (See below for discussion of IP address and subnet mask.)
There are several protocols that routers use to direct messages to their destination. Two of the
most common are Open Shortest Path First (OSPF), which is typically used in large enterprise
networks, and Border Gateway Protocol (BGP), which is typically used on routers that run the
internet.
Since routers work with logical addresses and operate on the Network Layer of the OSI model,
they are often known as layer 3 devices.
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Under the current, most commonly used IP standard (IPv4), IP addresses consist of 32 bits, or
binary digits. The IP address is typically expressed as the decimal values of 4 bytes, each byte
representing 8 bits. For example, an IP address of 192.168.0.4 is actually the decimal
representation of the following:
11000000.10101000.00000000.00000100
( 192 . 168 . 0 . 4 )
An IP address is divided into two portions, network and host. The network portion of an IP
address represents the network to which the device belongs. Devices can only communicate
directly with devices that are on the same network. Devices communicate with other networks
through routers.
The host portion of the IP address represents the device, or interface of the device. A device
could have multiple interfaces, each with their own IP address. The host portion of the IP
address must be unique on the network, or IP subnet.
The Subnet Mask divides the network and host portion of an IP address. Like the IP address,
the subnet mask is a 32 bit number. For every bit of the subnet mask that is a “1,” the
corresponding bit of the IP address is part of the network portion of the IP address. Bits of the
IP address corresponding to a 0 in the subnet mask are part of the host portion of the IP
address.
For example, consider a subnet mask of 255.255.255.0. This would be written in binary as
11111111.11111111.11111111.00000000. This means that the first 3 bytes (24 bits) of the IP
address would be the network portion of the IP address and the 4th byte (last 8 bits) would be
the host portion. See the example below.
• Subnet Mask = 255.255.255.0
• IP Address = 192.168.0.4
• Network portion of IP address = 192.168.0.
• Host portion of the IP address = 4.
Devices that have identical network portions are on the same subnet and can communicate with
each other directly. Devices that have different network portions are on different subnets and
need to communicate with each other through routers.
The third parameter that needs to be specified is known as the default gateway address. This
refers to the IP address of the router located on that network. The network portion of the default
gateway address will be the same as all of the other devices on that network. Devices on the
network will need to go through this router to communicate with devices on other
networks. Routers use the IP address, subnet mask, and default gateway address to define an
efficient route between devices.
The term gateway is used here to refer to the connection point between two networks. In this
case that connection point is a router. In general, it is not appropriate to use the terms gateway
and router interchangeably.
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For instance, consider sending a start command to a generator set from a remote HMI
communicating by Modbus/TCP. The Modbus command (write the start bit to the appropriate
Modbus register on the generator set control) would be formatted with the appropriate security
data session layer. The transport layer on the HMI will add error checking info and will divide the
message into the appropriate segments. The Network Layer will add the IP address of the
sending and receiving devices and routing information. The data link layer will add
synchronization and frame integrity information and start and stop bits, and the physical layer
will send the frame out over the communication media. At the receiving device, the process
works in reverse as the layers decode the message while passing it up the stack until the start
bit gets set in the Modbus register of the generator set control. Figure 35 is a sample of the
frame construction.
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Figure 37 shows how the two models map to one another. Note that the mapping between the
models is not perfect. For example, there are elements of the OSI Session layer that are defined
in the Transport layer of the TCP/IP model. The differences between the two models are subtle
and are outside of the scope of this document.
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6.7.2 RS-232
RS-232 was developed by the Electronic Industries Association (EIA) to define the physical
interface between a PC and peripheral equipment, such as modems and printers. The RS-232
standard defines communication between two specific types of equipment known as Data
Terminal Equipment (DTE, typically a PC) and Data Communications Equipment (DCE, typically
a modem) over a distance of no more than 50 feet (15 meters). RS-232 also specified the pin
designations on the 9 and 25 pin connectors that were most common at the time. RS-232
defines separate transmit and receive wiring paths with the transmit pin on one device
physically connected to the receive pin on the other device. Although it was designed for a very
narrow scope of applications (communication between only two devices no more than 50 feet
(50 meters) apart), RS-232 is still commonly used in those applications today due to its
simplicity and relatively low cost to develop and deploy. Cummins Power Generation’s Mon
protocol, which is used by the InPower service tool to connect to controls, is built on the RS-232
physical layer.
6.7.3 RS-485
RS-485 was also developed by EIA as the standard for connecting more than two devices on a
network over longer distances. Unlike RS-232, which has separate circuits for transmitting and
receiving signals, RS-485 specifies a single circuit for both transmitting and receiving signals,
known as a transceiver. The RS-485 transceiver is designed in such a way that multiple
transceivers can be connected to the network without affecting the one transceiver that is
transmitting a signal. RS-485 was designed so that signals can travel long distances without
being attenuated by resistance and inductance in the wires and have a high level of noise
immunity.
RS-232 allowed two devices to send messages at the same time by having separate send and
receive paths between the two devices. Since RS-485 uses only a single transceiver for both
transmitting and receiving data, this is not possible. At any given time, a device may either
transmit or receive data but the device cannot perform both operations. This is known as half-
duplex communication. There is also a 4-wire implementation available on the market which
supports full-duplex communication. These devices consist of 2 separate RS-485 transceivers,
so that one can transmit and the other can receive at the same time.
Cummins Power Generation’s PCCNet protocol, used to communicate between a generator set
and its accessories, such as human machine interfaces (HMIs) and annunciators, is built on the
RS-485 physical layer. RS-485 networks can communicate with up to 32 devices at half duplex
at distances up to 4000 feet and can be expanded by using repeater products available on the
market.
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6.7.8 Modbus
Modbus protocol was published by Modicon in 1979 for use with their PLCs and has become a
de facto standard industrial communication protocol. Modbus uses a master/slave format and
was originally developed to communicate over a serial link, typically RS-485. There were
originally two forms of Modbus; Modbus RTU and Modbus ASCII, with the difference being in
how the data bits were packed into a frame. Modbus RTU packs the bits more efficiently
(meaning the overall message length is shorter to convey the same amount of information so
the network runs faster) so Modbus ASCII is rarely used today.
Modbus TCP is becoming more popular as TCP/IP and Ethernet protocols are becoming more
common in control networks. At the application layer, Modbus TCP is the same as Modbus
RTU. The difference is in how the data is transported at the lower layers.
Another version of Modbus, Modbus+, is available on the market. It uses a peer-to-peer token
passing communication scheme (as opposed to master/slave) and is capable of running at 1
MBit/s. Modbus+ requires a dedicated co-processor and is proprietary to Schneider Electric so
its use is limited to applications where high speed communication is critical. Cummins Power
Generation uses Modbus+ for internal communication in some Digital Master Control (DMC)
applications.
6.7.9 LonWorks
The LonWorks platform was developed by Echelon Corporation and is used primarily in building
automation systems, particularly in HVAC and lighting systems All seven layers of the protocol
stack are implemented using Echelon’s Neuron chip. Although technically an open protocol, it is
very difficult to develop LonWorks products without buying the Neuron chip. Installing LonWorks
networks typically requires an integration tool. Echelon's LonMaker commissioning tool is most
commonly used for this purpose. Use of LonMaker requires paying a royalty per device
commissioned.
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LonWork’s standard network variable types (SNVTs) and peer to peer communication gives
integrators a great deal of flexibility in developing a customized network, particularly when
working with devices from different manufacturers. Manufacturers are also able to create their
own User-defined Network Variable Types (UNVTs) giving them the ability to optimize their
application of LonWorks for their equipment.
Cummins Power Generation controls have used LonWorks communication since the mid-1990s,
however, in recent years the preference in Cummins Power Generation’s key critical protection
markets has been for Modbus communication at the application layer and RS-485 and Ethernet
at the lower layers. Cummins Power Generation controls are moving towards supporting
Modbus for 3rd party communication and a proprietary protocol for communicating between
Cummins products.
6.7.10 BACnet
BACnet is a data communication protocol used mainly in HVAC and lighting control networks.
BACnet was developed with the guidance of the American Society of Heating and Air
Conditioning Engineers (ASHRAE). BACnet is an application layer protocol and interfaces with
several data link and physical layer protocols, including RS-232, RS-485, and Ethernet. BACnet
applications have also run with LonWorks data link and physical layers.
It is not uncommon to have LonWorks and BACnet devices on the same network and there are
many Lon to BACnet converters commercially available. In most cases, individual devices on a
network do not need to communicate with each other, but need to communicate with a common
building management computer running a commercially standard SCADA package. Most
SCADA packages will have standard drivers for Modbus and many will have drivers for
LonWorks as well. Most often it is not necessary to convert LonWorks or Modbus devices to
BACnet for all devices to be monitored and controlled by a single Building Management System.
6.7.11 Profibus
Profibus was originally developed in Germany in the late 1980s and was initially used and
promoted by Siemens. It was developed for use in factory and process automation systems with
the intent of reducing the wiring required to communicate between a central controller and
distributed sensors and actuators. Profibus protocol defines all seven layers of the OSI
model. There are several different physical layer implementations including RS-485. Profibus is
a proprietary closed protocol and is not openly published.
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6.7.14 PCCNet
PCCNet is a Cummins Power Generation’s proprietary protocol used exclusively for
communicating between a generator set or switchgear controller and its peripheral devices,
such as HMIs, annunciators, and expanded I/O modules. It is not used to communicate with any
3rd party equipment or monitoring system. Limiting the types of devices that can communicate
over PCCNet makes it a simple network to use and to support. PCCNet is a plug and play
network, with no configuration required for devices to communicate. The plug and play
characteristic simplifies service as well because no special tools are required to replace
components
PCCNet communicates over an RS-485 physical layer.
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7 Monitoring Systems
7.1 Overview
This chapter describes monitoring systems, and defines purposes and basic functions. On-site
supervisory control and data acquisition (SCADA) systems and web-based monitoring systems
are explored, and typical applications for each type of monitoring system are described.
Considerations for communicating between Cummins Power Generation’s equipment and 3rd
party monitoring systems will be explained.
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Some service organizations bundle a remote monitoring service with a planned maintenance
agreement because the monitoring system allows the service organization to operate more
efficiently. For example, a low fuel notification may be sent directly to a fuel delivery contractor
who can re-fill the fuel tank without any prior interaction with the service organization or end
user.
A monitoring system will allow service organizations to have better visibility of when
maintenance is required. When there has been an alarm, the monitoring system may allow the
service organization to do some diagnostics before dispatching a technician to the site so that
technicians will have the parts they will likely need and will more likely be able to repair any
problems with the generator set on the first trip to the site.
An end user may also be able to use a monitoring system to minimize the operating costs of the
system. Having access to fuel consumption and energy usage data can help make decisions on
questions, such as when to run the facility on generator power versus utility power and whether
there is value in operating equipment at times of day when energy costs are lower.
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FIGURE 39. HMI DISPLAY OF SINGLE LINE DIAGRAM AND STATUS OF PARALLELED
GENERATOR SETS
In the example displayed in Figure 39 an operator can get more detailed analog data of
individual generator sets by clicking on one of the generator sets on the HMI. Figure 40
displays the screen that appears from clicking on one of the generator sets on the HMI
displayed in Figure 39.
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Logging data over time allows organizations to mine data in an attempt to better understand
how the system works, to optimize system operation. Knowing how much energy is used, at
what time, and by which loads, can help facility owners operate their facilities more efficiently.
Figure 44 displays a plot of a log of real power used in a facility over a period of 10 days. This
particular plot does not differentiate between power supplied by the utility versus power supplied
by a generator set. It enables a facility owner to better understand the energy demands of the
facility and make decisions accordingly.
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Even data taken at 5 minute intervals can eventually exhaust the available memory of an on-site
monitoring system, so provisions have to be made to move this data to a permanent archive.
This is typically accomplished using a “store and forward” scheme in which the system
periodically sends data to some offsite archive. Data archiving routines can be implemented
automatically using a pre-set schedule or can be initiated by an operator.
7.3.4 Reporting
Agencies, such as JCAHO and the EPA, require reports documenting system
parameters. Almost all monitoring systems with data logging capability have at least a basic
reporting capability.
Monitoring systems generate reports simply by exporting logged data into a format that can be
used by an end user or technician’s personal computer (PC). Acrobat and Excel are the most
common formats used for reporting, although in some cases, to avoid compatibility issues,
monitoring systems will export data in a very simple “Comma Separated Value” (.csv) format. A
.csv file is simply a text file with fields separated by commas which can be imported into many
spreadsheet or word processor programs using many different operating systems.
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7.4.1.2 Drivers
A driver, in the context of a monitoring system, is a software program that allows the data
acquisition application to communicate with the monitored equipment. It converts data between
the format used by the data acquisition software and the protocol used by equipment. Drivers
are typically supplied by the data acquisition software supplier and several different drivers will
be available in support of the program. For example, a data acquisition software product may
have drivers available for Modbus, LonWorks, and BACnet, and it is permissible to use more
than one driver in a particular application. A monitoring system may simultaneously use BACnet
to communicate with heating and air conditioning equipment and Modbus to communicate with
power generation and distribution equipment. It is not necessary that all monitored components
use the same protocol as long as the monitoring system has drivers to support all of the
protocols used in the system.
All of Cummins Power Generation’s generator sets are capable of communicating over Modbus
to enable communication with SCADA systems. Modbus is the most common application layer
protocol used in SCADA systems and most SCADA packages have a Modbus driver as a
standard offering. When system specifications call out communication with a SCADA system
using some other protocol, the first course should always be to inquire whether a Modbus driver
is available for the SCADA system. In most cases, a Modbus driver will be available at a low
cost. Adding the Modbus driver will be a much simpler, less expensive and more reliable
solution than performing a protocol conversion, which will require a 3rd party gateway and
custom programming.
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Remote access is most commonly provided through the internet and the Pulse system can be
provided with a web server as an option. End users and service technicians will be able to view
system status and download reports and data logs remotely through the web as they would for a
web-based monitoring system. Although this scenario does provide the benefits of a web-based
system, for purposes of this discussion, the Pulse system is still considered an on-site rather
than web-based monitoring system because typically the primary day-to-day users of the
system are on-site and all of the data manipulation happens on-site.
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While there are advantages to using a corporate network for external communication, it is
important to isolate the automation network from the corporate network for many reasons. One
key reason is to make the amount of traffic on the automation network be unaffected by traffic
on the corporate network. This is important since the automation network depends on the
network for controlling devices in real time. See Figure 48.
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In applications in which there is no internet access, an off-site web server is the only choice for
web-based monitoring. In addition, an off-site web server has advantages when the monitoring
system is in use by a service organization to service multiple installations. Data from multiple
installations can be sent to the same web server and displayed on a single web page so that
service technicians only need to access a single web page to view status on all of the
installations for which they are responsible. Figure 50 represents a web page listing generator
sets from multiple installations.
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8 Communication Systems in Power
Generation Applications
8.1 Overview
This section descibes several different applications using network technologies. In general,
these were developed to contribute to maximizing system reliability and minimizing operating
costs. Networks, when combined with appropriate service and maintenance procedures, provide
the infrastructure to achieve these goals through the key functions of status display and control,
alarm notification, and data logging, analysis, and reporting. In this chapter we will look at a few
examples of networks that serve the customer well in this respect. Some of these networks are
very simple and some seem quite complex, but they all increase reliability and reduce operating
costs by executing the same functions. Even the complicated networks can be understood by
breaking them down into the simple concepts discussed in this manual.
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The grocery store networks are a very simple yet very effective web-based monitoring system
achieved by understanding exactly the end user’s needs and limitations, and designing a
system to fit the application.
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The SCADA system communicates over Modbus. Each of the generator sets has a LonWorks
card. A ModLon gateway converts the Lon data from the gensets to Modbus so that the SCADA
system can use it. The fourth generator set has a LonWorks to Ethernet router located at the
generator set so that the Lon data can be communicated over the internet. A second LonWorks
to Ethernet router puts the data back on to the LonWorks physical layer so that it can
communicate through the ModLon gateway to the SCADA system. The network also has an
iWatch web server so that alarms can be delivered and system status can be viewed
remotely. Figure 52 is a block diagram of the network.
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Both networks use a similar architecture at a high level. The generator sets are all connected to
a LonWorks network. Data from the Lon network is converted to Modbus by the ModLon
gateway located within the DMC cabinet where it is read by a Programmable Logic Controller
(PLC) which is part of the DMC. The PLC has an Ethernet connection which is connected to an
Ethernet switch to which all of the transfer switches are connected through fiber optic cable. The
airport system also has a Pulse system connected to the Ethernet switch. Figure 53 is a
representation of how the gensets, the DMC, and the Ethernet switch are connected.
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Several of the RTCPs that are located in the same general area are connected over Cat 5 cable
to an Ethernet switch which will connect to the rest of the facility using fiber optic cable. The
Ethernet switch is also connected to a PLC which manages some discrete I/O. The start
command from the ATS, for example, doesn’t go through the RTCP but goes directly to the PLC
as a discrete input. Figure 54 is a representation of the RTCP and the Ethernet switch.
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9 Appendix
9.1 Glossary
Address
An identifier used to uniquely identify nodes on a control network.
Annunciator
An annunciator is used to give remote indication of the status of an operating component in a
system. Annunciators are typically used in applications where the equipment monitored is not
located in a portion of the facility that is normally attended. The National Fire Protection
Association (NFPA) has specific requirements for annunciators in some applications, such as
hospitals.
Backbone
Typically a fast cable or fiber connection used to connect wiring closets, hubs, and switches. In
a bus topology the backbone is the bus.
Balun
A balance resistor placed between two cable sections of a network to give the entire cable a
consistent characteristic impedance.
Bandwidth
The amount of data that can be transmitted in a fixed amount of time. For digital devices it is
usually expressed as bits per second or bytes per second. For analog devices it is usually
expressed as cycles per second or hertz.
Baud Rate
The speed of data transmission in serial data communications approximately equal to the
number of code elements (bits) per second (BPS). Bits per second are also termed BPS with
the prefix (k) denoting thousands.
Binding
The process of making the logical connections to the network (also called connecting). This
involves connecting network variable outputs to network variable inputs using LonMaker for
Windows software.
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Bit
Binary Digit (i.e., a 1 or 0).
Boolean
A logical system used to express one of two states, such as on or off (yes or no, 1 or 0, etc.)
Bus
The main physical data-carrying media of the network data wire. It must be terminated at both
the start and end of the network. The wire is daisy-chained from one node to the next. The
Lonworks network bus cannot exceed specified length (which varies by cable type used) without
the use of a router. Stubs off the main bus wire of a Lonworks network cannot exceed 10 feet (3
meters). Bus can also refer to the physical power-carrying connection between generator sets
and loads in a paralleling system.
Bus Topology
All devices are connected to a backbone cable or bus. The bus topology is relatively
inexpensive to install. Typically both ends of the bus must be terminated.
Byte
For the purposes of control networking, a byte can be defined as a set of eight contiguous bits.
Cellular
Refers to a communication system that divides geographic regions into sections called cells.
The purpose of this division is to make the most use of the limited number of transmission
frequencies.
Channel
A channel is the physical communications media that connects the devices. Most
PowerCommand network installations will have only one channel (UTP cable and 78 kBPS
transmission speed). In a large network, there may be multiple channels and each channel may
or may not be of the same media type. Typically, channels are linked together using routers.
Characteristic Impedance
A parameter of communication cable. The impedance that an infinitely long section of cable
would have.
Client
A client is a device that accesses a service or shared data on another device or server.
Typically, clients would require specific permissions and software in order to utilize the services
or data on the server.
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Configured/Unconfigured
The term configured, as used in Lonworks networks, refers to a module that has been logically
installed with LonMaker software. A network image (address and binding information) is stored
in the node. A module that has not been logically installed with LonMaker is referred to as being
unconfigured. The service LED will blink on an unconfigured module.
Connecting Devices
Connecting refers to the process of assigning connections; linking an output variable of one
device to an input variable of another device. This process is also called binding.
Daisy Chain
A wiring method where each device on a network is wired in series.
Deterministic
A network characteristic meaning that the time it takes a message to be transmitted between
two nodes is predetermined and consistent. Networks that are used for time critical control
functions need to be deterministic.
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Domain
A domain is a network concept that allows independently functioning networks to share
resources such as transmission media. A domain designation provides an ID number to identify
the devices that can communicate within that domain. A network must have at least one
domain. PowerCommand Network installations will usually have only one specified domain.
Echelon
The name of the company that developed the Network Protocol Lontalk and some of the
Lonworks products used by CPG.
Ethernet
Ethernet refers to network products and structures covered by the IEEE 802.3 standard. Three
data rates are currently defined for operation over optical fiber and twisted-pair cables: 10
Mbps-10BaseT, 100 Mbps-100BaseT, 1000 Mbps-Gigabit Ethernet. Ethernet is the most
prevalent LAN technology. It is easy to understand, implement, manage, and maintain.
Firewall
Server or system used to block unauthorized access to a network, while allowing authorized
access.
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Frame
A sequence of bits that is part of a message communicated between two devices. A message to
be communicated is broken down into frames so that it will fit within the parameters of the
protocol. A typical frame will consist of identification of the sending and receiving devices,
control information, data and data integrity bits. The control information is used to signal the
beginning of a new frame, describe how the message is segmented (how this frame fits into a
larger message), and how it is to be routed. Data integrity bits are used to verify that the
message has been received correctly.
Gateway
A device that acts as an interface between two different communication protocols.
Hub
A hub is a network device that serves as the center point of a star configured network, enabling
other network devices to be connected. A hub broadcasts any message it receives to all other
devices connected to its ports.
Latency
The amount of time it takes a packet of information to travel from its source to its destination.
Master/Slave Network
A type of network operating system whereby one device controls all communication on a
channel. This controlling device is known as the master. The slaves are all other devices on a
network. This is different than the peer-to-peer type of network operating system.
Media
The physical path used for transmission of messages between network nodes. Media can be
twisted pair wiring, through the air (wireless), or fiber optic cable, among others.
Modem
Modulator Demodulator. A device that converts a computer’s digital pulses into audio
frequencies (analog) over a telephone line and converts them back into digital pulses at the
receiving site. Typically, one modem will transmit the data and another will receive the data over
a telephone line at a controlled transmission speed.
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Modbus
Modicon’s Modbus protocol is an old protocol, by technology standards, that has become a de
facto standard for generic network devices and in some cases for devices using different
technologies that need to communicate. Most manufacturers of control devices and protocols
have included the ability to communicate with Modbus protocol. Some examples of different
Modbus implementations:
• Modbus ASCII – ASCII characters are used to represent the data in Modbus ASCII
messages. This is a serial protocol typically communicating over an RS-232 connection.
Modbus ASCII is considered an Open Protocol.
• Modbus RTU – One RTU character is used to represent the data in Modbus RTU
messages. This is a serial protocol typically communicating over an RS-232 or RS-485
connection. Modbus RTU is considered an open protocol.
• Modbus TCP – Modbus TCP is a proprietary TCP/IP based protocol that communicates
over an Ethernet network. The data structure of Modbus TCP is similar to Modbus RTU.
Modbus Plus
An industrial networking system that uses token-passing peer-to-peer communications at data
transfer rates of one megabit per second (MBPS). The network media is shielded twisted-pair
cable.
Network
A collection of nodes that communicate with one another over a common medium (i.e., wire,
fiber, wireless) where information is exchanged via sets of rules (protocols).
Node
The term "node" is a general term used to refer to any device communicating on a network.
Operating System
The operating system is the system software that is responsible for the direct control and
management of the system's hardware and internal control operations.
Parity
In error detecting schemes, parity is a bit (even or odd) that represents the binary sum of the
data transmitted. Primarily used when transmitting data over a long distance.
Peer-to-Peer
A network operating environment where any device on the main network bus can initiate
communication.
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Port
The external connector on a device at which the network cable or medium is attached.
Private Network
Network that uses private network address (LAN) (192.168.x.x, 172.16.x.x, 10.x.x.x)
Protocol
Set of rules used mutually by two or more devices or software applications to communicate.
Different protocols often describe different aspects of a single communication; taken together,
these form a protocol stack. Different protocols function at various levels of the protocol stack.
For example, the TCP/IP protocol is a transport protocol that functions at the lower levels of a
protocol stack, where Modbus is an application protocol that functions at the upper levels of the
protocol stack.
Protocol Suite
A collection of protocols that are designed to work together. Protocols such as HTTP, HTML,
SMTP, SNMP, TCP, and IP are often described as being part of the internet protocol suite.
Ring Topology
All devices are connected to each other in a closed loop, or ring. Each device is connected
directly to two other devices. Ring Topology networks are very reliable.
Router
A router is a device that directs network traffic between two networks. The term router is used in
relation to control networks to apply to devices that encapsulate and receive data over different
networks or media. Routers receive packets of data, filter them, and forward them to a final
destination using the best route. Most LAN and WAN routers direct packets of data based on
TCP/IP addresses. Routers do not send broadcast packets or corrupted packets. If the routing
table does not indicate the proper address of a packet, the packet is discarded.
Serial Port
A communication port at which data is transferred one bit at a time.
Server
A server is a device that provides services or resources, such as printers and files, for the use
of other devices on the network.
Slave
A networked device that is controlled by another device. Slave devices do not initiate data
transmission. They respond to commands or requests initiated by a master device.
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Star Topology
A topology where all the devices must connect to a central hub. Star topologies are relatively
easy to install and manage but can have bottlenecks occur as all the information must pass
through the hub.
Subnet
The subnet defines a logical grouping of nodes in a network and is part of a node’s network
address.
Subnet Mask
A mask used to determine which sub-network an IP address belongs to. Logically, the purpose
of the subnet mask is to take a particular IP address and divide it into smaller sub-networks
connected by Ethernet routers.
Switch
A switch is a multi-port device that allows devices to attach to a network in the star
configuration. A switch receives data and sends the data only to the port with the intended
recipient attached.
Token
In data transmission, a frame passed on a network that gives a networked device the current
authority to transmit.
Token-Ring Topology
All of the devices or nodes are connected to one another in the shape of a closed loop. Ring
topologies are relatively expensive to install, but they offer high bandwidth and can span larger
distances.
Topology
The physical shape of a network. There are three principal topologies: multi-drop bus, token-
ring, and star.
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9.2 Acronyms
Acronym Description
A/D Analog to Digital
AC Alternating Current
ACB Air Circuit Breaker
ANSI American National Standards Institute
AS, or AUS Australia
ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Materials
ATS Automatic Transfer Switch
AVR Automatic Voltage Regulator
AWG American Wire Gauge
BACnet Building Automation and Control Networks
BIL Basic Impulse Level
CAN Controlled Area Network
CB Circuit Breaker
CCC Certification agency of the Peoples Republic of China
CCM Controls Communication Module
CE Conformite Europeenne
CGT Cummins Generator Technologies
CSA Canadian Standards Association
CSV Comma Separated Value
CT Current Transformer
dB Decibel
DC Direct Current
DHCP Dynamic Host Configuration Protocol
DIM Digital Input/Output Module
DMC Digital Master Control
DNS Domain Name System
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Acronym Description
E-Stop Emergency Stop
ECM Engine Control Module (control for emissions-compliant engines)
ECS Engine Control System
EMI Electromagnetic Interference
EIA/TIA Electronic Industry Association/Telecommunications Industry Association
EN European Standard
EPS Engine Protection System
FAE Full Authority Electronic (Engine or Control)
FMEA Failure Mode Effect Analysis
FMI Failure Mode Identifier
FSO Fuel Shut Off
GB Gigabyte
GCS Generator Control System
GEN Alternator/Generator
Genset Generator Set
GFCI Ground Fault Circuit Interrupter (North America)
GND Ground (Earth)
GOOSE Generic Object Oriented Substation Events
GOV Governor
HMI Human Machine Interface (Operator Panel)
I/E Import/Export Control
IC Integrated Circuit
IEEE Institute of Electrical and Electronics Engineers
ILS Isochronous Load Sharing Control
IP Ingress Protection (primarily used in IEC markets)
ISO International Standards Organization
kVA Kilovolt-amps (a measure of load power consumption or alternator capacity)
kVAR Kilovar (a measure of reactive power)
kW Kilowatt (a measure of real power)
LAN Local Area Network
LCD Liquid Crystal Display
LCL Low Coolant Level
LED Light Emitting Diode
LLC Logical Link Control
LNS LonWorks Network Services
LSIG Long, Short, Instantaneous, Ground Fault (reference to CB trip unit)
MAC Media Access Control
MB Megabyte
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Acronym Description
Mil Std Military Standard (USA)
NC Normally closed; or, Not Connected
NEC National Electrical Code (NFPA 70, the US National Electrical Code)
NEMA National Electrical Manufacturer’s Association (Primarily in N America)
NFPA National Fire Protection Association
NO Normally Open
NWF Network Failure
NZ New Zealand
OEM Original Equipment Manufacturer
OOR Out of Range
OORH, or ORH Out of Range High
OORL, or ORL Out of Range Low
OSHA Occupational Safety and Health Administration (U.S. government entity)
OSI Open Systems Interconnection
PB Push button
PC Personal Computer
PCC PowerCommand Control (A Cummins control system)
PF Power Factor
PGI PowerGen Interface
PGN Parameter Group Number
PI Proportional/Integral
PID Proportional/Integral/Derivative
PLC Programmable Logic Control
PLL Parallel/Paralleling (usually in reference to a paralleling control)
PMG Permanent Magnet Generator
PT Potential Transformer
PTC Power Transfer Control
PWM Pulse-Width Modulation
RFI Radio Frequency Interference (susceptibility or transmission)
RH Relative Humidity
RMS Root Mean Square
RTU Remote Terminal Unit
SAE Society of Automotive Engineers
SCADA Supervisory Control and Data Acquisition
SNMP Simple Network Management Protocol
SPN Suspect Parameter Number
SW B+ Switched B+ (B+ DC power supply available when engine is running)
SYNC Synchronizer
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Acronym Description
T-011 Transfer Switch Application Manual (Cummins)
T-016 Paralleling Application Manual (Cummins)
T-030 Generator Set Application Manual (Cummins)
TCP Transmission Control Protocol
THD Total Harmonic Distortion
UL Underwriters Laboratories
UPS Uninterruptible Power Supply
UTP Unshielded Twisted Pair
VT Voltage Transformer (same function as PT)
WAN Wide Area Network
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