July 2003 - System Overview Technical Data Table Of Contents System General 2 Applications for System 2 The Need For Lighting Control 2 Energy Costs 2 Software Control 2 Secure Network & Distributed Intelligence 2 Reduced Construction Time & Space 2 Lighting Control With No Additional Structures 2 Lighting Control With No Additional Labor 2 Product Support & Technical Assistance 2 Network Philosophy 3 System Nodes General 3 Control Nodes 4 Universal System Controller 4 Switch Override Controller 4 Telephone Override Controller 4 Application Specific Controller 4 Network Access Devices 5 Network Access Device Selection 5 System Software 6 Software Levels 6 Pow-R-Command Workstation Requirements 6 Protocol Exchange Controllers 7 Native Controllers vs. Servers 7 Native Controllers 7 Servers 7 Network 8 Typical Networks 8 Technical Resource Library 10 TD01412010E For More Information visit www.cutler-hammer.com
Page 2 Effective: July 2003 General System The system is a complete network of devices, which allow a facility s electrical use to be efficiently managed. With the individual loads can be switched through a resident network, at individual panels, and can be controlled through switch inputs (Building Automation Systems, wall switches, etc.), software, or through telephone commands. Applications for System The system is primarily designed for larger facilities where multiple nodes need to be networked together and controlled through software. However, Pow-R-command 100 can also be scaled down to the needs of some smaller facilities while offering the same functions as a large networked system. The Pow-R- Command 100 system provides an easy manner to efficiently control electrical loads while maintaining a compact design. In addition, the system can be seamlessly integrated into Building Automation Systems, Security Systems, and Fire/Emergency Systems. The Need For Lighting Control In all businesses, no matter the type, there are any number of variables that can have a significant influence on its profitability and the supped that profit is realized. Among these variables are the electrical consumption, construction time, and the ease employees use the facility. Eaton s Cutler- Hammer system can have an impact on all of these elements. Energy Costs Among the various factors that contribute to total energy costs are the times that energy is used, and the amount of energy used at any point in time. can help control both of these. With integral time control and the ability to stagger the start time of groups of devices, the Pow-R- Command 100 system can help a facility manage their electrical consumption. Further more, a system can be integrated with a metering system to further monitor and control electrical use. Software Control Through the software multiple lighting panels can be networked together sharing information and directing each other based on established commands. In addition to control of time schedules, switch inputs, and holiday schedules, Eaton s Cutler-Hammer has developed software allowing users to remotely monitor system activity and view system data over the Internet. To make interaction with the system even more user friendly, an optional software package is offered to allow custom graphic screens to be developed, integrated into the system, and even viewed over the Internet. To make integration of a Pow-R-Command 100 system even easier, optional software packages have been developed for integration through OPC Servers, and software that is compliant with Microsoft s.net architecture. Secure Network & Distributed Intelligence Each node on the network is an independent controller with the necessary memory and processing power to control its own function. In addition, each controller has the ability to send commands to other controller(s) and process commend sent to it. When all control nodes are networked to a system head, each controller will accept global commands and synchronize time and control functions. Because each control node can act independent of the network, if the network goes down the lights continue to operate. If this was not the case, and panels acted as slaves to other panels or the network, then if the master controller on network failed, the slave controllers would fail. Reduced Construction Time & Space In each panelboard are a revolutionary device known as a Smart Breaker TM. Eaton s Cutler-Hammer Smart Breaker combines the interrupting ability of a standard branch circuit breaker with a remote switching ability. Smart Breakers mount in any standard Cutler-Hammer brand panelboard, and can be intermingled with standard branch circuit breakers. Because no additional structures are needed to mount Smart Breaker, the extra material & labor from contactor or relay cabinets is eliminated. TD01412010E For More Information Visit www.cutler-hammer.com Lighting Control With No Additional Structures The controllers, as well as Smart Breakers, mount directly into a standard Cutler-Hammer brand panelboard. Such panelboards would be required in a facility even if no lighting control is installed. As a result of this, the system and all of its abilities can be installed in the same structures that would normally be required. Lighting Control With No Additional Labor When using contactors or relays to control lighting there are four basic element that need to be integrated into a circuit. This includes a standard branch circuit breaker mounted in a panelboard, a relay or contactor mounted in a separate cabinet, a controller mounted in a cabinet, and the lighting loads. On the job site, the contractor would need to pipe and wire from the controller and branch circuit breaker to the contactor or relay and then to the lighting load. Because the controller, branch device, and remotely controlled switching device are allocated in one structure, the contractor only needs to pipe and wire from the panel to the lighting load. Product Support & Technical Assistance Eaton s Cutler-Hammer has 17 locations that are fully capable of manufacturing and supporting the product. In addition, a technical and applications engineering services are available, and can be reached Monday through Friday 8:00 a.m. to 5:00 p.m. EST at (803) 481-6811. In addition to technical support, Eaton s Cutler-Hammer offers a field engineering service, which is available for field study and coordination of electrical and lighting control systems.
Page 3 Effective: July 2003 Network Philosophy The System is designed to provide the user with the greatest flexibility for interfacing with it. The system cleanly integrates into a number of larger system both through device level & system level communication, or can stand alone as a complete networked control system. Operator Work Station/Software Network Access Device System Nodes General The system basically consists of five different types of devices. Each of these nodes is described briefly here and given more detail in the following pages. Control Nodes: Control nodes are assigned the duty of controlling switching devices as well as creating groups and time schedules. Control nodes include the Universal System Controller, Switch Override Controller, and Telephone Override Controller. All of these controllers are located in Pow-Rcommand 100 structures such as panelboards (See Technical Document TD01412013E). Pow-R- Command 100 Switch Override Controller is used to allow additional switch inputs (e.g. wall switches) to be integrated into the Pow- R-Command 100 network. The Pow-R- Command 100 Telephone Override Controller, as the name implies, allows the facilities telephone system to be integrated into the network. For more information on Pow-R- Command 100 Universal System Controller/structures, Switch Override Controller, and Telephone Override Controller, see Technical Documents TD01412011E, TD01412012E, & TD01412013E respectively. Network Access Devices: Network Access Devices are the head of the Pow- R-Command 100 network. Pow-R- Command 100 Network Access Devices provide entrance to the Pow-R-Command 100 network and commonly act as a master controller For complete information on the Network Access Devices see Technical Document TD01412014E. To BACnet System Panelboard Relay Cabinet w/ Switch Override Controller RS-485 Network Figure 1: Basic Network & Components Operator & User Workstations: The Pow- R-Command 100 system is programmed trough software. In order to make use of the ability of the software packages, it is necessary to use a computer. This includes desktop PC s, laptop PC s, and Pocket PC s. For more information on PC use with the Pow- R-Command 100 system please see Technical Document TD01412016E. Software: All functions of the Pow-R- Command 100 system must first be established in software and then transferred to the control nodes through Network Access Devices. To provide the greatest amount of flexibility in software control, there are five separate levels of software that are sold separately. These five levels are discussed further in this document. BACnet Gateway TD01412010E For More Information Visit www.cutler-hammer.com Telephone Override Controller Protocol Exchange Controllers: In some facilities it is necessary to integrate the system into a Building Automation System (BAS). The product can support the use of BACnet, Modbus, Lonworks, and Johnson Controls N2 protocol. For more information on BACnet, Modbus, & Lonworks see Technical Document TD01412018E. For more information on integration with Johnson Controls N2 protocol, see Technical document TD01412017E. Network: The backbone of the Pow-R- Command 100 system is the RS-485 network which runs between the control nodes and other components. The Pow- R-Command 100 network and nodes act relatively independently of each other. This means that if a controller fails the network will remain intact, and if the network fails controllers in a stand alone or back-up mode.
Page 4 Effective: July 2003 Control Nodes In the system, control nodes are used to hold & process local programs, process commands sent to and from each control node, and to switch devices. There are three separate types of control nodes in the system. These include the Universal System Controller, Switch Override Controller, and Telephone Override Controller. Each controller has on-board memory and processing power. Universal System Controller Telephone Override Controller The Telephone Override Controller allows the Pow-R- Command 100 system to be integrated into the facilities PBX system. The Pow-R- Command 100 Telephone Override Controller allows the facility s occupants to control designated lighting through a series of custom voice prompts. For more information on the Telephone Override Controller see Technical Document TD01412012E. Application Specific Controller The Pow-R-Command 10 Application Specific Controller is designed for remote mounting, and can bring Pow-R-Command 100 functionality to otherwise dissimilar equipment and systems. For more information on the Application Specific Controller, please see Technical Document TD01412024E. The Universal System Controller is responsible for switching devices such as Smart Breakers and relays. Universal System Controllers can be mounted in Pandlboards, Relay Cabinets, Control Cabinets, & Column Type Panels. Furthermore, panelboards can be mounted into Eaton s Cutler-Hammer Integrated Facility Systems Switchboards. For more information on the Pow-R- Command 100 Universal Systems Controller, as well as structures, see Technical Document TD01412013E. Switch Override Controller Telephone Override Controller Control Cabinet The Switch Override Controller is used to provide additional switch inputs to the system. Because each control node is connected through a network, each switch input (e.g. wall switch) can be programmed to act like it is attached to every controller on the network. Each Switch Override Controller adds the availability of 48 2-wire inputs to the entire network. The benefit of this is having the ability to control switching devices (e.g. Smart Breakers) by a photo sensor located at the other end of the network. The Switch Override Controller can also act as a convenient device for consolidating all switch inputs into one location. Like the Universal Systems Controller, the Switch Override Controller can be mounted in a Panelboard, Relay Cabinet, or Control Cabinet. For more information on the Pow-R- Command 100 Switch Override Controller see Technical Document TD01412011E. Column Type Panel Panelboard Relay Cabinet Figure 2: Structures & Control Nodes TD01412010E For More Information Visit www.cutler-hammer.com
Page 5 Effective: July 2003 Network Access Devices Network access devices are essentially the starting point for the system. Each Network Access Devices acts to accomplish several functions including protocol exchange, system synchronization, establish the network, and access to the network. Protocol Exchange: The Pow-R- Command 100 network uses RS-485 to communicate across nodes. In order for a device such as a PC, which operates on RS-232, to communicate with the network a translation must take place. In addition to RS-232, Network Access Devices are available for translation to TCP/IP for Ethernet communication. System Synchronization: Each node on the network contains a database. This database contains essential operating information as well as programmed functions. Likewise, each Network Access Device contains a database. The database in the Network Access Device acts as a global database. Functions and programs that effect the entire network are stored on the Network Access Device. In addition, the Network Access Device contains the master clock. Each day all nodes on the Pow-R- Command 100 network access the Network Access Device to synchronize all clocks on the network. Network Interface Box Local Access Analog Modem To Phone System Remote Access Remote or Local Access Unitary Modem Interface RS-232 Others Including BACnet, Modbus, & Lonworks See Technical Document TD01412014E Network Type Desired Ethernet Server Ethernet Using TPC/IP Establishes the Network: The Network Access Device is used as the starting point of the network. Each network can consist of 120 nodes, including the Network Access Device. Under circumstances where more then 120 nodes are necessary in a facility, multiple Network Access Devices are used. Each Network Access Device acts as the head of the network that it is attached to. Access to the Network: The Network Access Device is used to provide users access, through software, to the network. This is done through PC s. The network can be remotely accessed through a modem or Ethernet. Figure 3: Decision Tree of Network Access Devices Network Access Device Selection The system has several types of network access devices available to assure the greatest amount of flexibility of use. The four most common network access devices are described in the following. For further information on Network Access Devices see Technical Document TD01412014E. Unitary Modem Controller: Translates RS- 485 to RS-232 and is commonly used for remote access, through a modem, to an unmanned system. TD01412010E For More Information Visit www.cutler-hammer.com Network Interface Box: Like the Unitary Modem Interface the Network Interface Box translates RS-485 to RS-232. The Network Interface Box is mounted adjacent to a PC, and is used in facilities with manned systems. Ethernet Server: The Ethernet Server translates RS-485 to TCP/IP. The Ethernet Server allows the network to be accessed through an Ethernet connection. Ethernet Server Plus: The Ethernet Server Plus combines the ability of the standard Ethernet Server, and add to it the function of a repeater and router.
Page 6 Effective: July 2003 System Software All of the power and ability of the Pow-R- Command 100 system is only achieved through use of software. software allows a facility to set schedules, create groups, track use, and communicate with other software programs. Software Levels To make sure that a facility has only what they really need to run their system, primary levels of software have been created. These levels of software are: Lighting Optimization Software: Allows for basic set up of network and all devices attached to it. Please see Technical Document TD01412015E for more information on the Lighting Optimization Software. Custom Graphics & Data Logging: The Custom Graphics and Data Logging software allows users to collect, store, and trend system information such as run-time cycles. In addition the Custom Graphics and Data Logging software package allows custom screens to be built into the Pow-R- Command 100 system giving users a more comfortable environment to work in. Please see Technical Data TD01412022E for more information on the Pow-R- Command 100 Custom Graphics & Data Logging Software. Web Server Software: Allows custom screens, trended/logged data to be viewed over Internet Browser such as Microsoft Explorer or Netscape Navigator. For more information on the Pow-R- Command 100 Web Server Software, see Technical Document TD01412023 for more information on the Web Server Software. OPC Server Software: OPC Software uses industry standard protocols to facilitate in exchange of information between separate software packages. For more information on the Pow-R- Command 100 OPC Server Software please see Technical Document TD01412020E. Figure 4: Miscellaneous Screen Views Of Lighting Optimization Software In addition to the previously listed Pow-R- Command 100 software packages a light version of the Lighting Optimization Software has been created for use on Pocket PC s. This gives users the ability to preform basic diagnostic and maintenance to individual controllers. For more information on use of Pocket PC s with a system, please see Technical Document TD01412016E. Workstation Requirements All levels of software requires the following minimum requirements for operation. In addition, the Web Server software, as the name implies, must be mounted on a PC used as a server. IBM Compatible PC Intel Pentium-90MHz Processor or Better Microsoft Windows 95B, 98 Second Edition, 2000, 2000 Professional, XP Home, or XP Professional At Least 32MB RAM Hard Drive With At Least 40MB of Free Space. Additional Space May Be Necessary Depending On Presence & Number Of Custom Graphic Screens & amount of trended data. Hayes Compatible Modem (Optional) SVGA Monitor CD-ROM Drive - All Software Comes Standard On CD-R. If Necessary Software Can Be Placed On 3.5 Floppy Disk. Network Interface Card (For Use Only With Ethernet Server or Web Server Software) TD01412010E For More Information Visit www.cutler-hammer.com
Page 7 Effective: July 2003 Protocol Exchange Controllers The System is designed to provide the user with the greatest flexibility for interfacing with it. In most circumstances, the Pow-R-Command system uses an RS-485 protocol and communication standard to send and receive commands between control devices. In some circumstances, the Pow-R-Command 100 network must be able to integrate, through software communication, into larger systems. These larger systems are commonly titled Building Automation Systems (BAS). Currently the system can communicate across four protocols: BACnet Modbus Lonworks Johnson Controls Inc. N2 Protocol For more information on integration using BACnet, Modbus, & Lonworks see Technical Document TD01412018E. For more information on integration using Johnson Controls N2 protocol see Technical Document TD01412017E. Native Controllers vs. Servers Making a distinction between integrating systems into other systems, there are two methods that need to be noted. These two methods are native controllers and server devices. When a controller is native it only speaks the language of the system it is in. For instance the controllers used in a standard Pow-R- Command 100 system are native to Pow-R- Command 100; all these devices speak to is other native devices. At times circumstances may dictate that native controllers cannot be used. This includes instances where native products with specific function do not exist. In cases such as this, a server devices is used to translate data between the two systems. Depending on the application the Pow-R- Command 100 system both methods may be used. HVAC System Fire/Emergency System Security/Access Control System Other Mechanical Control System Building Automation System Modbus/RS-485 Network Maximum Network Length 4,000-Feet (1.2 Kilometers) Using Twisted Shielded Pair Panelboards w/ Modbus Native Controllers Installed Figure 5: Modbus Enabled System On A Modbus Network Native Controllers Eaton s Cutler-Hammer currently offers three native controllers for use in Pow-R- Command 100 Panelboards, Relay Cabinets, Control Cabinet, and Column Type Panels. These native controllers only speak the appropriate language and adhere to the appropriate signal standard. Pow-R- Command 100 Native Controllers include: Standard Controller Using RS-485 Modbus (ASCII & RTU) Using RS-485 Johnson Controls N2 Using RS-485 Server Devices Server devices act, as the name implies, to serve commands sent from requesting system. Currently, two server devices have been designed for use with the Pow-R- Command 100 system. The first server is the BACnet server. The BACnet server allows data and command to be translated between the system and a BACnet system using standard BACnet commands and protocol. BACnet command are send from the BACnet server over a CAT5 cable and in accordance to the Ethernet standard. The second server is the Pow-R-Command 100 SOAP server, which allows for communication based on SOAP standards. Because of its complexity, the Pow-R- Command 100 SOAP server has a technical document devoted solely to it. For more information on the SOAP server please see Technical Document TD01412021E. TD01412010E For More Information visit www.cutler-hammer.com
Page 8 Effective: July 2003 SOAP Server Network The backbone of the system is the network that runs between each control device. In native Pow-R- Command 100 systems, including Modbus and Johnson Controls enabled Pow-R- Command 100 systems, the network consists of an RS-485 signal running on a twisted shielded pair network cable. This network allows for commands and data to be sent from control node to control node and from control node to workstation. In the case of a standard Pow-R-Command 100 system, the network is independent of the controllers. This means that if a controller fails, the network will maintain continuity. This is in opposition to systems that use a Master-Slave type relationship, where one control node connects to the network and further control nodes connect to it. If the master control node fails, network communication to the slave control nodes also fails. As the network is independent of control nodes, the control nodes are also independent of the network. When using standard control nodes as well as the Modbus Native Controller, each controller has on-board memory, battery backup, and processing power. Because of this, the programming for each control node s operations can be stored and processed directly on the board. If this was not the case all commands would have to be sent from a central or master controller. Storing the programming information on each board helps to assure that any network failures do not effect the operation of the control nodes. Looking back at the master slave relationship, if a network failure occurred, the slave controllers would not know how to act and would essentially do nothing until the network was restored. Network Specifications: RS-485 is a standardized protocol and transmission method. As such, standards have been created for its use, and apply to the system. The following standards pertain only to Pow-R- Command 100 systems that do not use Modbus or N2 Native Controllers. Maximum Network Distance 4,000-Feet (1.2 Kilometers) Without Use Of Repeater Maximum Number of Nodes 120 Twisted Shielded Network Cable: BELDEN 3105A, 300V (Preferred) BELDEN 82841, 300V, Plenum (Preferred) BELDEN 9841, 300V BELDEN 89841, 300V BELDEN 3074F, 600V (For Custom Applications) Network Maximum Distance 4000-Feet Using Shielded Twisted Pair Network Cable Node 2 Node 1 RS-485 Network Maximum Distance of Network 4000-Feet from Network Access Device to Furthest Node UsingShielded Twisted Pair Network Cable Universal System Controller Mounted In 5X Control Chassis Network: + - SHLD Node 3 Network: + - SHLD Network Access Device Network specification for a Modbus enabled system will very depending on the complexity of the Modbus system. Network specifications for a Johnson Controls N2 enabled Pow-R- Command 100 nodes are based on the N2 specification itself. For more information on the Pow-R- Command 100 network see Technical Document TD01412014E. For more information on Modbus enabled Pow-R- Command 100 systems, see Technical Document TD01412018E. For more information on the N2 enabled Pow-R- Command 100 controllers see Technical Document TD01412017E. Typical Networks The following figures illustrate some of the network possibilities of the Pow-R-Command 100 system. These figures are for illustration purposes only. Figure 6: Network Wiring Example TD01412010E For More Information visit www.cutler-hammer.com
Page 9 Effective: July 2003 130-Feet 300-Feet Floor 3 90-Feet 110-Feet 250-Feet 140-Feet 40-Feet Floor 2 150-Feet 270-Feet Floor 1 Network Distance Calculation Measured In Feet Network Sections = 150 + 270 + 40 + 140 + 250 + 110 + 90 + 130 + 300 Total Network Length From Network Access Device = 1,480-Feet Total Figure 7: Typical Network Riser Diagram With Daisy-Chained Network Drops Wireless Access Point User PC with Microsoft Internet Explorer or Netscape Navigator Web Server Software Lighting Optimization Software Custom Graphics Software Operators Station/Server With Pow-R-Command 100 Web Server Software, Custom Graphic Screens Software & Lighting Optimization Software IP Address: 188.329.28.388 Ethernet (LAN) PRC100 Network 1 Facility 1 Ethernet Server IP Address:188.329.28.389 PRC100 Network 1 Facility 2 Ethernet Server IP Address:188.329.28.390 Maximum 300-Feet From Hub/ Server/Work Station User PC with Microsoft Internet Explorer or Netscape Navigator User PC with Microsoft Internet Explorer or Netscape Navigator RS-485 Network Max Distance 4,000-Feet RS-485 Network Max Distance 4,000-Feet Figure 8: Typical Network Architecture With Multiple Users and Facilities With Web Server Software TD01412010E For More Information visit www.cutler-hammer.com
Page 10 Effective: July 2003 Pow-R-Command Technical Resource Library For additional information on Networks and components, please refer to the appropriate Technical Document. Technical Documents for the System are as follows: Title: PRC100-System Overview PRC100-Switch Override Controller PRC100-Telephone Override Controller PRC100-Panelboard, Relay Panel, & Column Panel PRC100-Networking PRC100-Software PRC100-Human Machine Interfaces PRC100-Johnson Controls N2USC Controller PRC100-Protocol Exchanges PRC100-1-10V dc Dimming Electronic Ballasts Control PRC100-OPC Server PRC100-Microsoft.NET PRC100-Custom Graphics & Data Logging PRC100-Web Server Software PRC100-Application Specific Controller PRC100-Low-Voltage Relay Card Publication Number TD01412010E TD01412011E TD01412012E TD01412013E TD01412014E TD01412015E TD01412016E TD01412017E TD01412018E TD01412019E TD01412020E TD01412021E TD01412022E TD01412023E TD01412024E TD01412025E For the most current list of documents on the system, please visit www.cutler-hammer.com. Eaton Corporation Cutler-Hammer business unit 1000 Cherrington Parkway Moon Township, PA 15108 United States tel:1800-525-2000 www.cutler-hammer.com 2003 Eaton Corporation All Rights Reserved Printed In USA Form No. TD01412010E