Interface Note #0907-01 R4
Contents
1. J Default Gateway 132 J168 J0 j1 Rear View of Orion5r Subnet 1 Subnet 2 DNS B S B PEIO I Switch fide a Ethernet Settings for Card 2 Fe Converter as See C Obtain an IP Address automatically JL required by the f Use the following IP Address application rs e Oe beaa lira Subnet Mask 255 255 255 fo g Default Gateway 192 fies fo fo Figure 3 Suggested physical Ethernet connection between Orion and the PCM DNS B S B Figure 2 NCD configuration screen for dual Ethernet Note different subnets required Interface Note 0907 01 cont D 3 and Orion5r Integration Using Modbus over Ethernet Modbus TCP Orion Configuration Summary Novalech Bitronics D 3 Orion All Orion configuration is performed offline using a free issue software program named NovaTech Communications Director or NCD In order to understand how Orion is configured it is important to first understand how Orion is typically applied Orion serves as a protocol converter and data concentrator in most industrial applications In these roles Orion reads data from attached IEDs and presents these data to attached Masters As graphically depicted in Figure 4 to the right Orion typically reads only a portion of the available data from attached Slave IEDs as many IEDs contain hundreds or thousands of points Orion normally uses preconfigured pick lists or Default Files to simplify the selection of which points to read If a Defa2. Novalech Bitronics D 3 Orion Interface Note 0907 01 R4 D 3 and Orion5dr Integration Using Modbus over Ethernet Modbus TCP Moving real time data and control commands between the D 3 Process Automation System and field devices through the Oriondr Automation Platform using Modbus TCP requires configuration know how as well as an understanding of the application and the specific field devices field connections and data types This note highlights key configuration steps and provides background material to properly set up this interface lt is also possible to establish a Modbus serial connection or a Modbus Plus connection between the Oriondr and the D 3 In most installations however Modbus TCP will provide a more cost effective and flexible solution at lower cost Contents Design and Application of the Orion Automation ProceSSOT ccc cece cee ee cece eee eee ee eee esas eneeeaeeaeegaeeategnenaees 2 Typical Applications of Orion in Process Plants ccc ccc cece cece eee eee eee eee eee ene e eae seen ee eae eee e eae e ante ena e ea taes 2 Orion Models for Ind strial Plans c ren r EEE EE ee see ee ee ote ora eee ere nse Ie 3 Summary of Interfaces Between Orion5r and D 3 Modbus Serial Modbus Plus and Modbus TCP 3 Details of Physical Ethernet Connections between Orion and D 3 ccc ccc cece eee eee ence eee eaeeeeeeaeeaeteeeeaeeeeeaes 4 Single Dual E
3. 5 If a Default File is not available points from an IED can still be configured to be read Within NCD the user can always select New and then manually type in the name and address of the point to be read See Figures 8 and 9 below Modbus Master Eg Point Parameters Paint Hame Register Length Y Register Type dbus Master N IED pene a Outputs PollGroups Pusher eager m Modbus Master 1 r Point Parameters transformer 1 temp Point Name transformer 1_temp F Register Length Register Register Type linteger x Group Default Poll Group Display Pile Device NewlED All Devices bi Register 140005 Listed By Device Address Accept Cancel Hew Port Options Bit Co Move Delete Close 5 Delete Close Display Filter Min Value fo fan Devices Max Value 65535 Group Default Poll Group v C Bit Min Max Values Figures 8 and 9 showing configuration of a new point for an ery IED for which there is no Default File r Device Address oa New Delete Port Options Copy Move Delete Close Interface Note 0907 01 cont D 3 and Orion5r Integration Using Modbus lt o NovaTech over Ethernet Modbus TCP Bitronics D 3 Orion Bit Byte Order Guidelines Modbus Protocol The arrangement and numbering of bits and bytes transferred with the Modbus Protocol
4. Comm Fail Bitronics Comm Fail Demo 3515 inte Comm Fail amp Demo 3515 FMD_LED Demo 3515 Register Type 153 Comm Fail FLO FMD _LED13 Demo 3515 Display Screen Setup Reg 1 Status FMD LED Demo 3515 RTU JRTU 1 Display Screen Setup Aeg 25tatus amp FMD LED20 Demo 3515 Display Screen Setup Aeg 3 Status E FMD LED21 Demo 3515 40100 Display Screen Setup Reg 4 Statue E FMD _LED2 Demo 3515 Register Display Screen Setup Aeg 5 Status FMD LED23 Demo 3515 Feeder Amps PLC FMD LED24 Demo 3515 C Bit tf Min Max Values Feeder cronsh cor FMD LED25 Demo 3515 4 FMD_LED26 Demo 3515 This is the number Display Filter Display Filter we changed to AI Ports AI Devices modify the data is LLL ul sey cS B values presented to Alphabet Alphabet a Accept Cancel the PCM Port Options opy Move Delete Close Figure 15 NCD Configuration screen for data points presented to the Modbus Master by the Orion Slave 10 Interface Note 0907 01 cont ED Novalech D 3 and Orion5r Integration Using Modbus over Ethernet Modbus TCP Bitronics D 3 Orion Analog Data Scaling continued Scaling Situation 2 No Real Time Measurement Can Be Made In this case it is not possible to make a real time measurement of the actual value being read by Orion from the IED and the value is not displayed on the IED faceplate In this situation it is necessary to review 1 The primary power connections CTs and PTs to be made to the
5. eer 17 Interface Note 0907 01 cont D 3 and Orion5r Integration Using Modbus lt o Novalech over Ethernet Modbus TCP Bitronics D 3 Orion Design and Application of the Orion Automation Processor Orion is designed to provide real time data from electrical substations and processes in response to requests from data acquisition and control systems such as the D 3 The data provided by Orion typically originates in attached IEDs Intelligent Electronic Devices such as meters protective relays and specialized controllers Orion is also designed to receive output commands e g OPEN or CLOSE breakers from manual operators or control systems and to send those commands to IEDs or output modules In electrical substations the application of Orion is not considered critical in terms of ensuring operator safety protecting substation equipment or keeping the lights on Other local equipment in the substation will OPEN and CLOSE breakers automatically in response to electrical short circuits and other abnormalities The real time data provided by Orion is important for operators to view power flows and breaker status but typically not critical to maintaining power flow or processes Most modern substation IEDs can now store data with time stamps if Orion ceases to poll for data Most of the time there is little data to report from a remote substation because the nature of the electrical system operation is steady state When electric
6. fraction 23 bits rs 1 1 olofofofaJo a 2 2Jo 2 2 o 1 o 1 ololofofofo o o ojojojojojo 118 625 E 31 23 0 Bit values for the IEEE 754 32bit float 116 625 ls Interface Note 0907 01 cont Novatech D 3 and Orion5dr Integration Using Modbus Etronics OES amp OTe over Ethernet Modbus TCP Definitions continued Half duplex and Full duplex on Ethernet Half duplex works optimally only if one device is transmitting and all the other devices are receiving otherwise collisions occur When the collisions are detected the devices causing the collision wait for a random time before retransmitting This means that at half duplex Ethernet throughput is limited by the need to retransmit data when collisions occur Half duplex is the most common transmission method and is adequate for normal workstation and PC connections Full duplex provides dual communication on a point to point connection and allows each device to simultaneously transmit data and receive data on a connection Full duplex mode is typically used to connect to other switches or to connect fast access devices such as workgroup servers M 0 Half duplex with transmit and receive on a single pair 1 Receive lt Transmit Receive SS Full duplex with transmit on one pair and receive on EE E e T A a a Ethernet cable Transmit IED Common acronym for an Intelligent Electronic Device such as a meter protective relay or specialized contr
7. 1 cont D 3 and Orion5r Integration Using Modbus over Ethernet Modbus TCP Sending Control Outputs from D 3 Through Orion to IEDs As shown in Figure 18 to the right Orion is designed to accept control and setting commands from Master devices such as the D 3 and to route and convert these commands to IEDs Typical commands sent from the D 3 through Orion to IEDs include TRIP open circuit breakers and switches attached to IEDs CLOSE circuit breakers and switches attached to IEDs Open Close other physical IED outputs Change IED settings Change IED mode of operation When Modbus TCP is used between the D 3 and Orion the commands from the D 3 will either be single multiple coil write or single multiple register write Orion is configured to accept these Modbus commands and convert into the specific control commands understandable to the IED When coils are written to Orion Orion looks for the 0 to1 or 1 to 0 transition and reacts as configured Orion does not hold the written state of the coil so if the state of the coil is read back by the D 3 it will not reflect what was written Nearly every IED requires a specific and proprietary command from Orion or multiple commands from Orion to respond as required Although control commands from the D 3 can usually be mapped over to the IED without any special logic in Orion sometimes logic is required For example some IEDs require a command to close and a command to open wi
8. 13 0 4095 1000 1000 Vars Phase B 1 Register Integer 40014 0 4095 1000 1000 Vars Phase C 1 Register Integer 40015 0 4095 1000 1000 ICT Ratio1 1 Register Integer 40016 500 9999 500 9999 Figure 6 Portion of Default File for eight Bitronics Meters with Modbus protocol Modbus Master Port 4 Modbus Master Pot Devices inputs Default T agnames Amperes Phase Amperes Phase B Amperes Phase C Communications Firmware Rev Configuration Setup Register 1 Status Configuration Setup Register 251g CT Ratio Divisor Status CT Ratiot List of all points available to be read from the Bitronics Meter These points are from the Default File dAmps C Demand Amps N Demand YARs Total Modbus Master Amperes Phase Meter 237 Amperes Phase B Meter 237 Amperes Phase C Meter 237 Point Parameters Point Name Amperes Phase Register Length Register Type Integer x Device Meter 237 z Register 40002 Group Default Poll Group x C Bit Min Max Values 1 Register oe vv Points selected to be read Listed By Alphabet v Meter 237 v Min Value 2047 Max Value 4095 Dark Mabima Display Filter Meter 237 v Listed By Device ddress v Figure 7 NCD Inputs configuration screen 6 lt NovaTlech Interface Note 0907 01 cont Bitronics D 3 Orion D 3 and Orion5r Integration Using Modbus over Ethernet Modbus TCP Default Files continued
9. IED 2 The IED manufacturer s documentation to determine how measured values are presented Background CTs and PTs Three phase All power system IEDs require primary power values to be stepped down to distribution feeder levels which can be measured This is most often accomplished through the use of current transformers CTs that step currents down to 1A or 5A per SS phase and voltage potential transformers PTs that step voltage down to p 120VAC per phase All power system values Volts Amps frequency VArs Three voltage and three current Watts harmonics etc can all be calculated by the IED based on these CT and connections one to each phase PT inputs CTs and PTs are purchased in various ratios to present measurable values to the IED e g the higher the primary voltage the greater the CT ratio to present Power Meter a measurable value or Protective Relay If we are to understand the value presented by an IED we need to know the CT and PT ratios IED Manufacturer Documentation Although some IEDs present power system values in engineering units in real quantities as measured 200 Amps 12 000V etc most IEDs present values in counts which have to be correlated with the real value A formula is usually provided in the user documentation or can be obtained from application engineers to perform the conversion lt is also important to understand the data type s used by the manufacturer Smaller numbers
10. N voltage from the Nexus 1250 Meter The meter RES returns a value of 3677 This is 3677 counts or 5 610742 of full scale scale is 0 to 65535 This 250 Phase A N Comm Fail Nexus1250 INP100 1 J OF1 Voltage Nexusi250 I 45325 Polls Nexusi250 INEPi0 COM1 115200 None 8 1 Start Capture Reset OrionS Reset Orionl6 Disconnect Data values for Port 22 Point Number Responses Nexusi250 INP100 1 aTatatata VYVYVYUY a Port Status corresponds to a value of 123VAC as measured by PAPANE SS a volt meter LockedRelayStates2 Nexusi250 457393 RelaySelectionStatus Nexusi25 3013 00001 LockedRelayStates Nexus1250 I 4601 00000 0 000000 UU Ve VUUUUY UUVUU We want the D 3 to read 123VAC not 3677 We can present 123 to the D 3 by making 123 5 610742 of a new scale See arithmetic below 123 is 5 610742 of what number 123 05610742x solve for x 2192 If we present Phase A N voltage to the D 3 ina range from 0 2192 the value will be scaled properly and the D 3 will read 123VAC See Figure 13 below showing configuration screen for data presented to the PCM 0 Cct a Nexus 1250 meter NETWORK Modbus Slave Modbus Slave Co RTUs gt Tagname List Comm Fail Nexus 250 1 F100 LockedRelayStates GiNexus 250 INP1 OL LockedRelayStates Hesus 250 INPIL Phase A N Voltage 2M exue1 250 INP1TO0 Polls Nexus 250 INP1TO0H1 RelaySelectionStatus Nexus 250 NP 1 RelaySelectionStatu
11. Slave MERETE For the four byte double word 01 02 03 04 escription ModTCP toPCM_ Description ModTCP to PCM the order would be pee 04 03 02 01 Intel Dword Order Intel 02 01 04 03 Modicon Modicon N Motorola East 01 02 03 04 Motorola When presenting data to the D 3 normally you will select Modicon Dword order New Delete Port Options Delete Close Figure 11 Selection of Dword double word order for presenting data to a Modbus Master 8 Interface Note 0907 01 cont D 3 and Orion5r Integration Using Modbus over Ethernet Modbus TCP Analog Data Scaling lt NovaTlech Bitronics D 3 Orion The data values retrieved from the devices attached to the Orion may be not be scaled properly for presentation to the D 3 Orion can convert data values as shown in the examples in this section When scaling analog data either of the following two situations may exist Scaling Situation 1 Real Time Measurement Can Be Made In this case a real time measurement can be made of actual value being read by Orion from the IED or the actual value is presented on the IED faceplate This real value can be correlated with the numerical value presented by the IED Scaling can then be set up accordingly to present the real value to the D 3 system as desired Scaling Example A See screen capture to the right Orion reads Phase Orionfront port A
12. T Select Ethernet module to which Orion _ i Node N ORION_SUBI i will be connected ETHO e Name ETH2 IP dd ETH3 ress 10 80 100 109 Step 2 Name the Orion Ethernet Node Protocol MODBUS TCP H ORION_SUB1 and Orion IP Kais Address 10 80 100 105 o B Select Protocol Modbus TCP Maximum f i Messages x Define Orion Modbus Address 1 Define Messages and Timeout Timeout 3 00 seconds R Failover Node Starting Address 490001 of Registers 100 cues Block Type RE AD Modbus Block Properties xj Mode MULTI Starting Address 4001 01 Options AA of Registers Write on Change oo 2 Step 3 Baise wane gt Define the Modbus commands and registers to read Trigger in Orion and written to in Orion In this example Polling Interval 1 00 sec Mode MULTI 100 registers starting at 400001 will be read from LL Orion each second a Write on Change a Cancel oes 2 registers starting at 400101 will be written to i ns Trigger Orion every second Polinginierval 1 0 sec cri lt gt EthernetMPC 1 0 Configuration Oj x File Options Help Select PCM LIQLA Configuration to left shows what we have configured above The PCM will read data from Orion and write data to Orion H S ETHO a 3 ROASTER as defined here A a BLK TYPE ADDRESS REGISTERS POLL TIME 000 READ 400001 0100 1 00 001 WRITE 400101 0002 1 00 Interface Note 0907 0
13. al system disruptions occur due to storms equipment failure or unusually high load then data is reported by IEDs and by Orion Logic and Control Orion is not designed to be a Programmable Controller or to control real time critical equipment and processes as it goes through a 10 to 60 second reboot cycle when new configurations are loaded and activated Orion does offer a math and logic tool kit for data manipulation and simple control Redundancy Orion is not designed for bump less hot failover redundant applications because the primary substation application for which it was designed is not critical Two Orions can be configured in a cold back up redundancy scheme one powers up and runs if the other goes down which is described in this document Orion is offered with up to two Ethernet ports but in the current version these are not designed to be redundant This is further described within this document Typical Applications of Orion in Process Plants Orion is typically applied in both plant process areas and in plant substations Figure 1 below describes the devices to which Orion is attached and the typical inputs and outputs between Orion and the PCM Po Fates ranger e ee a Plant Substations i Breaker i Real Time Real Time process data Settings Amps Volts TRIP o Watts VArs COmmands and settings outputs Vv inputs outputs p etc inputs Serially Accessed plant instrumentation using Serially Meters Pr
14. an us the IED for a week All Default Files become part of the NCD program available to all users 4 Default Files for nearly all IEDs commonly applied in Utility substations are available in NCD However fewer Default Files exist for the IEDs applied in ndustrial substations and process applications Device Company Name Bitronics Device Name PowerPlex Protocol Modbus Model1 MTWDE1B Model2 MTWDE2B Model3 MTWDE3B Model4 MTWDEC1B Model5 MTVWDEC2B Model6 MTVWDN1B Model7 MTWDN2B Model8 MTVWDN3B DeviceProtocol Modbus RTU SmartReading Yes IED Names and Models Serial Default comm parameters Point names data types ranges MaxRead 125 MaxWrite 100 Port Port 9600 8 1 Inputs Health Check 1 Register Integer 40001 0 65535 0 65535 Amperes Phase A 1 Register Integer 40002 2047 4095 0 4095 Amperes Phase B 1 Register Integer 40003 2047 4095 0 4095 Amperes Phase C 1 Register Integer 40004 2047 4095 0 4095 Volts Phase A 1 Register Integer 40005 2047 4095 0 150 Volts Phase B 1 Register Integer 40006 2047 4095 0 150 Volts Phase C 1 Register Integer 40007 2047 4095 0 150 Watts Total 3 Phase 1 Register Integer 40008 0 4095 1000 1000 VARS Total 3 Phase 1 Register Integer 40009 0 4095 3000 3000 Watts Phase A 1 Register Integer 40010 0 4095 1000 1000 Watts Phase B 1 Register Integer 40011 0 4095 1000 1000 Watts Phase C 1 Register Integer 40012 0 4095 1000 1000 Vars Phase A 1 Register Integer 400
15. are usually presented as single register integers and larger numbers in two register integers with high and low register or in floating point format VArs and Watts are reported with a plus or minus sign based upon the direction of flow and are reported various ways For example the Bitronics MultiComm 3 Phase Multifunction Digital Meter reports VArs in the range from 0 to 4095 with O being 1000 VArs 2047 being 0 VArs and 4095 as 1000 VArs Note these VAr measurements are at the meter on the CT and PT secondaries The formula for conversion Value 2047 Actual VArs per phase 2048 x 1000 x PTratio X CT ratio This means that a value of 1500 returned by the Bitronics Meter with a PT ratio of 200 and CT ratio of 40 would calculate to 1205 2047 x 1000 x 200 x 40 2 136 719 VArs or 2 14 MVArs Handling Floating Point Numbers Some IEDs present data in two register floating point format to Orion These floating point analog numbers can be presented by Orion in Modicon Dword order and directly read into the D 3 using the FLT conversion type IEEE 754 32 bit floating point See D 3 documentation for more detail 11 Interface Note 0907 01 cont r Novalech D 3 and Orion5r Integration Using Modbus over Ethernet Modbus TCP Bitronics D 3 Orion Accuracy and Decimal Places In the scaling example on Page 10 note that the Ampere value presented to the D 3 93 Amperes was rounded to the nearest A
16. ct serial port can be RS232 RS485 or serial Fiber Optic Select protocol either Master or Slave for this port Configure serial port parameters baud rate address etc If Master select IED company and IED model then select points to be read If Slave select points to be presented to the Master If desired configure points numbers and scaling parameters 6 Configure IRIG B time parameters if present 7 Configure Network port Ethernet Follow same steps as in 4 above 8 Configure Add Ons if present which are Orion options for archiving data serving out web pages for Sequence of Events and Alarms and other options 9 Configure Hardware I O built into Orion 10 ATC and DA if present are specialized application for Utility customers and OEMs 11 Configure Logic if present Siem Communications Winde General Hardware Model Information Ports d IRIG B d Network Add Ons Hardware I O d ATC d DA d Logic d p Figure 5 Configuration selections for Orion within NCD Selections are based upon options ordered Interface Note 0907 01 cont D 3 and Orion5r Integration Using Modbus over Ethernet Modbus TCP Default Files Novalech Bitronics D 3 Orion In order to simplify the selection of values to be read from an IED NovaTech provides pre configured Default Files or pick lists for hundreds of commonly used IEDs These Default Files are spreadsheets that contain t
17. he addresses and names of the data points the high low range of the value and other communication parameters unique to the device Each IED and each protocol require Default Files a GE F60 protective relay with Modbus protocol uses a different Default File than the F60 relay with DNP3 protocol Default Files are provided as part of the configuration program for the Orion5r NovaTech Communications Director or NCD More about Default Files 1 The Default File is developed based upon what the IED manufacturer states is present in their standard communication map in their IED and is typically obtained from the IED user manual and other documentation If this documentation is inaccurate or if the points map has been modified by the user the Default File will also have to be modified 2 Creating and Editing Default Files can be accomplished by NovaTech Engineers or by the user An application note is available detailing how each spreadsheet row and column should be filled in When complete the new Default File is loaded in the Defaults directory within NCD 3 As a policy NovaTech will edit and develop new Default Files at no extra charge to the user We do request at least two to three weeks advance notice preferable while the Orion is on order and prior to delivery The Default Files for some protocols and IEDs can be complicated and may require testing with the IED prior to submission to the user we may require the user to lo
18. ices as all 100MB full duplex as this provides the highest level of performance and reduces the chances of experiencing communication failure Half duplex reduces throughput and mixing 10MB and 100MB Ethernet devices requires Ethernet switches to be configured in auto sensing mode Auto sensing creates additional latency which can result in comm failure between PCMs For this reason it is preferable to specify Dual Ethernet full duplex 100MB Orion5drs in some plants rather than the single Ethernet Orion5 or Orion5r which are both limited to half duplex 10MB In this current Orion5r model the two Ethernet ports are not designed to be redundant instead they must be assigned different Ethernet subnets and must not reside on the same network this architecture was requested by Utility clients to ensure separation between the Ethernet network in the substation and the Ethernet network from the substation to the remote polling location See Figure 2 below In dual Ethernet Orion applications it is suggested to use one Ethernet network for handling real time data between Orion and the PCM and to use the second Ethernet network to connect to a networked PC for remote configuration and diagnostics See Figure 3 below Ethernet Settings for Card 1 C Obtain an IP Address automatically Use the following IP Address IP Address ue at fore ae Style 10BaseT 100BaseTX z Es e 10Base ase Subnet Mask 255 255 205 0
19. ired for the Orion5r D 3 interface This application note only details the Modbus TCP interface Protocol Modbus Serial Modbus Plus Modbus TCP Device Model Muitibus O a sr mmus Pa se Ethernet Card ether single or MEPs Card MA PEI MPC Card Serial Port Sofi lt gt D3 W 1 2 up Better Option DI3 W11 04 up Modbus Serial D3 W oup D3 W11 04 MBPlus Slave g ia DS wW amp up Slawe Protocol up Protocol 43 Required 47 GPXIO card Modbus Modbus Bridge to SST 5136 MDP Bridge to Type A RS232 Hardware MUL Card 85 PCI MBPlus Type B R5485 or dual Ethernet Required Card Type C Fiber Optic Conf AFG Utility POD Utility POD Utility Novatech POD Utility POD Utility Novatech MA Eth Config Novatech ontig Communication Communication Communication Software Director NCD Director NCD Director NCD Table 2 Modbus interfaces between the D 3 and Orion Interface Note 0907 01 cont lt o Novalech D 3 and Orion5dr Integration Using Modbus Bitronics D 3 Orion over Ethernet Modbus TCP Single Dual Ethernet Application Guidelines The Orion5dr is available with two Ethernet options single Ethernet or Dual Ethernet each using an RJ 45 style connector supporting Ethernet twisted pair The single Ethernet port option only supports 10MB 10BaseT while the Dual Ethernet option supports either 10MB or 100MB 10BaseT 100BaseTX Many D 3 users prefer to set up Ethernet networks and dev
20. mpere with no decimal point reported If a decimal place is desired making the value 92 5 Amperes change the scaling from 0 to 810 to 0 to 8100 and the value will be presented to the D 3 as 925 This in turn can be configured in the D 3 to be displayed as 92 5 See Figures 16 and 17 below for configuration guidelines lt lt NETWORK Modbus Slave Mod TCP Slave for D3 E x m Tagname List m Modbus Slave Point Parameters Amperes Phase 4 Bitronics a Amperes Phase B Bitronics Amperes Phase B Bitronics Register Lenath ji Register Amperes Phase C Bitronics Amperes Phase C Bitronics Comm Fail Bitronics Comm Fail Demo 3515 3 iter o Comm Fail Demo 3515 FMD_LED1 Demo 3515 Register Type g Comm Fail PLC Display Screen Setup Reg 1 Status RTU RTU 1 x Display Screen Setup Reg 2 Status Display Screen Setup Reg 3 Status Display Screen Setup Reg 4 Status Register fao oo Display Setup Reg 5 Status i Feeder Amps ere a C Bt Min Max Values Change this number from e gt FMD_LED26 Demo 3515 Bit zj 810 to 8100 to present an Display Filter Display Filter Min Value fo extra digit to the D 3 All P i i z j Al Pont 5l all Devices z present 925 instead of 93 Listed By Listed B Alphabet Alphabet m Port Options Move Delete Close Figure 16 NCD Configuration screen for data points presented to the Modbus Master AI Proper
21. oller used in the electrical system RS 232 A recommended industry standard RS for transmitting data RS 232 allows Full Duplex transmission which means there are separate transmit and receive signal lines enabling data flow in both directions simultaneously RS 232 uses an unbalanced signal mode meaning a voltage down a single wire is used to transmit receive binary 1 and 0 Often used for telemetry control systems where long cable runs are not required less than 100 feet Most devices use a DB 9 connector for RS 232 communication either DB 9F female DB 9M male although other connector types DB 25 RJ 11 screw terminal are used The DB 9M male pins are designated as shown below DB 9F are opposite 1 5 N ODGOOG OOOO G g RS 485 A recommended industry standard which permits data interchange on multidrop networks of up to 32 nodes using a single twisted pair cable In order for this protocol to be used each device on a network must be addressable Similar to RS 232 but uses a balanced signal mode A balanced signal mode utilizes a pair of wires where a voltage difference is used to transmit receive binary information A balanced voltage signal level travels faster and much longer distances than an unbalanced type up to 1500 feet Used extensively for telemetry control systems 18
22. otective Specialized serial protocols not supported by the D 3 system Accessed Relays Controllers e g Keithley Moisture Meter GE PH Meter etc 1 0 Modules Figure 1 Typical applications of Orion in process areas and in plant substations 2 Interface Note 0907 01 cont LO Novalech D 3 and Orion5r Integration Using Modbus over Ethernet Modbus TCP Bitronics D 3 Orion Orion Models for Industrial Plans Two Orion models are currently produced the Orion5 and the Oirondr The Orion5dr is offered with modifications required for UL Listing and the Orion5 is not If UL Listing is required the Orion5r should be specified The main differences between the Orion5 and the Orion5r are detailed in Table 1 below Size Serial Ports IRIG B Port Ethernet Ports Baud Rate Built In I O Orion5 6 4 wide up to nine No one optional 4in 2out 5 5 High 10BaseT 10MB 6 7 deep Half duplex Orion5dr 19 rack mount up to 17 Yes one optional port 4in 4 out 3 5 High 2RU 10BaseT 10MB 13 Deep Half duplex or two optional ports 10BaseT 10MB 100BaseTX 100MB Auto sensing Full duplex Table 1 Orion models for industrial plants IRIG B used to synchronize Orion s clock to an accurate external GPS reference for accurate down to 1mS time stamping of events Summary of Modbus Interfaces Serial Plus and TCP Between the D 3 and the Orion5r Table 2 below summarizes the software and hardware requ
23. ss Nexus 250 INF Responses N esus 250 INP1 0081 Listed B y Cee Modbus Slave Comm Fail Nexus1250 INPTOORT LockedRelapStates Nexus 250 INP1 O08 LockedRelayStates2 Nerus Zo0INPTOO Polls Nexus 250 IMP1O0F1 RelaySelectionStatus N exue 250 1NP1 OL Responses Nexus 250 IMP1TOOF1 Display Filter All Devices Listed By Phase A N Voltage GN exue1250 INP1008 E RelaySelectionStatus2 Nexus 250 INPIC lr Paint Parameters Register Type nteger ATU f Bit oa Minha Values Register Length 1 Register Register 140011 Figure 13 NCD Configuration screen for data points presented to the Modbus Master by the Orion Slave 9 Figure 12 Screen capture showing real time data values being read by Orion from This is the number we changed to modify the data values presented to the PCM Interface Note 0907 01 cont LO Novalech D 3 and Oriondr Integration Using Modbus Sa E over Ethernet Modbus TCP Bitronics D 3 Orion Analog Data Scaling continued Scaling Example B TELNET 192 168 0 100 23 x See screen capture to the right Orion reads Phase A Setup Connections Start Capture FesetOrionS Reset Orioni6 Disconnect Port Status Amperes from the Bitronics Meter The meter returns Data values for Port 2 Bitronics MTWDE1B p1 a val
24. system with objects and control commands specifically defined to pertain to monitor and control substation equipment Like Modbus DNP3 does not define the physical port the communications medium or the baud rate Unlike Modbus DNP3 does define portions of the application such as setting the time reporting by exception and establishing specific control sequences for circuit breakers DNP3 can be transmitted over an Ethernet TCP communications network Floating Point IEEE 754 The IEEE Standard for Binary Floating Point Arithmetic IEEE 754 is the most widely used standard for floating point computation The standard defines formats for representing floating point numbers together with a set of floating point operations that operate on these values IEEE 754 specifies four formats for representing floating point values single precision 32 bit double precision 64 bit single extended precision 2 43 bit not commonly used and double extended precision 2 79 bit usually implemented with 80 bits Only 32 bit values are required by the standard the others are optional For complete treatment see http en wikipedia org wiki IEEE_floating point_standard Two examples of single precision 32 bit floating point numbers sign exponent 8 bits fraction 23 bits P ofolafafafa afofo o a o o ojojo o o o o ojolololofofofolojojojo 0 15625 31 23 0 Bit values for the the IEEE 754 32bit float 0 15625 sign exponent 8 bits
25. t from the previous reading reset timer If coil 00258 is the same as the previous value do nothing Invert the state of the coil O to 1 or 1 to 0 and write to coil 00257 in Orion lf communications if good the timer should continually be reset and should not time out Orion Logic Create free running timer to initiate comm fail if not reset in x seconds Read internal coil 000257 The value will be either a 1 ora O Coil 00257 Coil If coil 00257 is different from the previous reading reset timer 00258 If coil 00257 is the same as the previous value do nothing both Initiate Communication Failure actions if timer times out lf communications if good the timer should continually be reset and should not time out Note that the inversion can be done in either the Orion or the PCM but not in both Interface Note 0907 01 cont D 3 and Orion5r Integration Using Modbus LO Novalech over Ethernet Modbus TCP bitrates Ole Orica Definitions Bit Byte Word 1 bit a single digit number in base 2 in other words either a 1 or a zero the smallest unit of computerized data Bandwidth is usually measured in bits per second 1 word 16 bits 2 bytes 1 double word 32 bits 4 bytes 2 words single precision floating point or integer 1 double precision word 64 bits 8 bytes 4 words DNP3 An IEEE standard for communication between computers within the substation and from the substation to SCADA DNP3 is a messaging
26. th a specific duration in between e g 0 5 seconds in order for a proper breaker TRIP to occur Typically the D 3 will write one command to Orion and Orion will contain logic to send the close open sequence to the IED Novatech Bitronics D 3 Orion Master 1 Master 2 Master 3 D 3 DCS other PLC other or DCS New New CLOSE TRIP Setting Slave Slave Slave IEDs IEDs IEDs Meters Protective Relays Instruments Figure 18 Orion accepting commands from Masters and sending commands to Slaves Novalech Interface Note 0907 01 cont Bitronics D 3 Orion D 3 and Orion5r Integration Using Modbus over Ethernet Modbus TCP Suggested Watchdog Circuit It is suggested that watchdog logic be created to monitor communication between the D 3 and the Orion such that action can be taken in the event of communication failure One common approach is to create a Digital Device in the D 3 that toggles bits in the Orion If the toggling stops after a predefined amount of time shutdown logic or other logic can be initiated on either side if necessary and additional process alarms can be triggered in the D 3 The diagram below further describes how this logic could be set up PCM Logic PCM Create free running timer to initiate comm fail if not reset in x Master seconds Read coil 000258 from Orion The value will be either a 1 or a O If coil 00258 is differen
27. the DDIO using DNP3 0 a common protocol used in the utility industry If these input states are required by the D 3 they can be presented in the Modbus protocol as bits coils or bits packed into registers When 24 input states are required by the D 3 and they are desired to be presented as bits packed into registers the following numbering conventions are used Inputs 1 through 24 I 123 45 6 7 8 9 10 1112 13 1415 16 1718 19 20 2122 23 24 24 in DDIO DNP Binary Inputs 0 through 23 Input circuit 1 is DNP3 0 binary input point 0 circuit 2 is DNP binary point 1 Any two Modbus registers with any bits representing inputs placed in any location in the registers NCD configuration software enables you to place bits wherever desired Note NovaTech Orion conforms to the original Modicon standard where the first bit in a register is 1 MSB and the last is 16 LSB ez Interface Note 0907 01 cont D 3 and Orion5dr Integration Using Modbus lt o Novalech over Ethernet Modbus TCP Bitronics D 3 Orion D 3 Configuration Summary The following steps describes the basic configuration of the D 3 to read data from Orion and write data to Orion For a complete description please refer to D 3 configuration manuals EthernetMPC 1 0 Configuration File Options Help Step 1 Select PCH Lioia Select PCM to which Orion will be lll Add Node Dialog D xj connected LIQ1A a
28. thernet Application Guidelines c ccc ccc cece ence eee cence ence eee eee eee ee eae e ates testes tests eset ean Eas 4 orlom cConiguratioh SuUmmnay meer aterm te i oe tr Sy earner emai ee em sree cere cer eee ee eee nme eet re ener eres eee eee ee ee 5 Default Files Pick Lists for Intelligent Electronic Devices IEDs Attached to Or ion c ccc cece cece ence ee ee es 6 Bit Byte Order Guidelnes m r a er tae ere ee oe eerie oe te ro ee eee ae ieee Gee ee meee eee oars 8 over LIT Eae eo Bc r Beale ei pena A ni te a en pu E E E cee eee eee nee 9 Handling Floating Pont NUMDEFS cee cece eee ese ee ee se isis ee mee seis ne ey eer sage oe soe eee eye ei eee eee 11 patorel Ug stone ale Bre e 1 1b E aa Cs 0 1 peeemele E eee ee ee eee eee eee 12 Accuracy of Power System Measurements ccc cece cece ence cece e ee eee eee e eae eee e eee e eee ee esse eae easeeaeeaeteneeaeegneeneas 12 Configuration Guidelines Presenting DDIO Input States to the D 3 Through Orion ccceceeeeee eee eee ees 13 DS Conhguralon summa n a a a ae re ee ee eee ee ee ee eee ee ee eee ee era 14 Sending Control Outputs from D 3 Through Orion to IEDS 0 cece cece ence e cence ee eee ease ee ea teat ea eeaeeeeeeeneeneenees 15 SUGGESTER WW atCNGOcuG In CUiy ert cece eae reer E ae erence 16 B77 TU 0 een eerste ene ere mtn a oer ae ee er ee ere eters eter en er oer ener ee re et et en
29. ties Remote Mode EPN BITRONAMPA EGULO 0 000 value 840939384741210 Pane 0 000 EGUTAG AMPS ALARMS z z SMOOTH fo E PHASE j Higoop sic e INADDR ETH 0 192 168 0 100 IN 400100 uo HIGOOD will Use 81 00 to display de additional significant digits mv al i Lopsp 10 000 INTYPE fal HIDSP 150 000 GAIN LLLIM 10 000 OcD LLCRIT YES HARDFAST Lui 1 9 000 cONY fun LCRIT No AMBS fo HLIM 750 000 BAMBS jo HcAIT NO 7 Scan Off Figure 17 Abbreviated WinMod Screen Capture Accuracy of Power System Measurements The accuracy of power system measurements is based upon the accuracy of the current and voltage transformers used to convert primary values to measurable values e g 1000 Amps to 5 Amps or 12 000 Volts to 120 Volts It is also based upon the analog to digital conversion accuracy of the meter or relay With the exception of revenue meters most power meters present data accurate to 0 25 to 1 Protective relay measurements are typically not as good down to 2 12 Interface Note 0907 01 cont LO Novalech D 3 and Orion5dr Integration Using Modbus So o o Bitronics D 3 Orion over Ethernet Modbus TCP Configuration Guidelines Presenting DDIO Input States to the D 3 Through Orion The DDIO module Distributed Discrete I O module is available in in thee combination of inputs and outputs 24in 16in 8out or 8in 16o0ut Orion communicates with
30. ue of 2282 This is 2282 counts or 11 474609 same so001 0 090000 of full scale scale is 2047 to 4095 where 2047 toner ee equals 0 Amperes and 4095 equals the maximum Baa a te Amperes able to be presented to the meter using the E EEE 40006 selected field transformers See page xx for a ee ea ina a eee emer description of the transformers used in power system W ees op measurements This corresponds to a value of 92 5 iiki ince paises Amperes as displayed on the meter faceplate O Vars Phase C Bitronics 40015 We want the D 3 to read 93 Amperes non decimal SSymgurnenetar no 92517 integer value not 2282 We can present 93 Amperes inal se aaa E ete to the D 3 by making 93 11 474609 of anew scale Rete reste 40023 See arithmetic below ESC Back C Column Editor S Sort Editor x D Dec O O0ct 93 is 11 474609 of what number 93 11474609x Figure 14 Screen capture showing real time data values being read by Orion solve for x 810 from a Bitronics meter If we present Phase A Amperes to the D 3 in a range from 0 to 810 the value will be scaled properly and the D 3 will read 93 Amperes See Figure 15 below showing configuration screen for data presented to the PCM NETWORK Modbus Slave Mod TCP Slave for D3 E Ea Point Parameters Amperes Phaze A Bitronics i Amperes Phase B Bitranics Amperes Phase B Bitronics Register Length fi Register Amperes Phase C bBitronics Amperes Phase C Bitonics
31. ult File is not available selected points can be typed into the configuration screen The following section of this application note further describes Default Files A portion of the data or all of the data read from Slaves can be presented to one or more Masters Even though the data may have come from a Slave using one protocol it can be presented to a Master in a different protocol The protocol translation is transparent Independent buffers for each Master are maintained to ensure Master 1 D 3 DCS Master 2 Master 3 other PLC other Masters read these data from Orion NN J orion is Slave to Master s J j X Orion is Master to Slaves Orion reads data from Slaves proper execution of control commands and data counters Also the Slave Slave Slave data presented to the Master can be scaled and numbered as IEDs IEDs IEDs desired by the user Meters Protective Relays Instruments Figure 4 Orion reading data from Slaves and presenting data to Masters Basic Orion configuration steps include 1 Install NCD on your PC All Orions are shipped with an NCD CD plus NCD can always be downloaded from the Orion User Support Site A Username and Password are required please call BJ Weil at 913 451 1880 to obtain if you do not have one 2 Open NCD 3 Configure General parameters user name password forcing points etc 4 Configure Orion hardware model IP addresses etc 5 Sele
32. varies from one implementation to another NovaTech conforms to the original Modicon standard where the first bit in a register is 1 MSB and the last is 16 LSB When Orion is configured to read data from a Modbus Slave one of the configuration parameters is the Dword or double word order of the data When NovaTech engineers develop the Default Files for an IED they include the Dword order as part of the Default File If you use a pre configured Default File provided by NovaTech you should be able to use the default setting for Dword order See Figure 10 below for an example of the Dword and other settings for an Electro Industries Nexus 1250 Meter NETWORK Modbus Master Modbus Master Device List Device Parameters Description Device Address Response Timeout mSec Retries Dword Order Intel Modicon Motorola Company Electro Industries v Read Write Parameters Smart Reading B Device Coil Read 1000 Register Read 125 Nexus1250 hoo Le Coil write f1000 Register Write 100 Delete Port Options Figure 10 Selection of Dword double word order for reading data from a typical Modbus Slave IED Nexus 1250 Meter When data is presented to a Modbus Master such as the PCM the Dword order can be selected When presenting data to the PCM normally you would select Modicon Dword order See Figure 11 below for a configuration example NETWORK Modbus Slave Modbus
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