Emerson E2 User manual

026-1903 Rev 4 19-APR-2010

E2 Controller Wiring Practices

1640 Airport Road Suite #104

Kennesaw, GA 30144

Phone 770-425-2724

Fax 770-425-9319

The information contained in this manual has been carefully checked and is believed

to be accurate. However, Computer Process Controls, Inc. assumes no responsibility

for any inaccuracies that may be contained herein. In no event will Computer Process

Controls, Inc. be liable for any direct, indirect, special, incidental, or consequential

damages resulting from any defect or omission in this manual, even if advised of the

possibility of such damages. In the interest of continued product development, Com-

puter Process Controls, Inc. reserves the right to make improvements to this manual,

and the products described herein, at any time without notice or obligation.

FCC COMPLIANCE NOTICE

This device complies with Part 15 of the FCC Rules. Operation is subject to the fol-

lowing two conditions: (1) this device may not cause harmful interference, and (2) this

device must accept any interference received, including interference that may cause

undesired operation.

CE COMPLIANCE NOTICE

Class A Product Information for Einstein, E2 Controllers:

The CPC Einstein and E2 controllers are Class A products. In a domestic environment

this product may cause radio interference in which case the user may be required to

take adequate measures. This covers:

• All Einstein family product types: RX - Refrigeration Controller

(830-xxxx), BX - Building/HVAC Controller (831-xxxx), and all ver-

sion models: (300, 400, 500).

• All E2 family product types: RX - Refrigeration Controller (834-xxxx),

BX - Building/HVAC Controller (835-xxxx), CX- Convenience Store

Controller (836-xxxx), and all version models: (300, 400, 500).

E2 Controller Wiring Practices Table of Contents • v

Table of Contents

1 OVERVIEW................................................................................................................................................................... 1

1.1. “NOISE” AND ITS EFFECTS............................................................................................................................................ 1

1.2. SOURCES OF NOISE....................................................................................................................................................... 1

2 AVOIDING NOISE-GENERATING DEVICES........................................................................................................ 2

2.1. CONTROL TECHNIQUES VARIABLE-SPEED DRIVES...................................................................................................... 2

3 AVOIDING HIGH VOLTAGE WIRING................................................................................................................... 3

4 USING THE CORRECT CABLE................................................................................................................................ 4

4.1. RS485 COMMUNICATION WIRING................................................................................................................................ 4

4.2. ANALOG OUTPUT WIRING (CONTROL TECHNIQUES VSDS)........................................................................................ 4

4.3. ECHELON NETWORK WIRING ....................................................................................................................................... 4

4.4. ETHERNET NETWORK WIRING ..................................................................................................................................... 4

4.4.1. Shielding................................................................................................................................................................ 4

4.4.2. Maximum Cable Length........................................................................................................................................ 5

5 POWER WIRE GAGE SELECTION ......................................................................................................................... 6

6 NETWORK STRUCTURE, BIASING, AND TERMINATION RESISTANCE.................................................... 7

6.1. RS485 NETWORKING.................................................................................................................................................... 7

6.1.1. Terminating and Biasing an I/O Networks and MODBUS Networks................................................................... 7

6.2. ECHELON NETWORKING ............................................................................................................................................... 8

6.2.1. Echelon Network Termination.............................................................................................................................. 9

7 CABLE AND DEVICE GROUNDING ..................................................................................................................... 10

7.1. GENERAL GROUNDING GUIDELINES........................................................................................................................... 10

7.1.1. Ground Wire Specifications................................................................................................................................ 10

7.1.2. Ground Source Specifications............................................................................................................................. 10

7.2. POWER INPUT AND RS485/MODBUS GROUNDING .................................................................................................. 10

7.2.1. E2........................................................................................................................................................................ 10

7.2.2. RS485 I/O and MODBUS Devices (except Control Link) .................................................................................. 11

7.2.3. Control Link Modules ......................................................................................................................................... 11

7.3. EMI-RESISTANT RS485 NETWORK GROUNDING PRACTICES .................................................................................... 11

7.4. VSD DRIVE GROUNDING PRACTICES......................................................................................................................... 12

7.4.1. Analog Output Cable Grounding........................................................................................................................ 13

7.5. ECHELON CABLE GROUNDING ................................................................................................................................... 13

7.5.1. EMI-Resistant Echelon Network Grounding (For High-EMI Environments).................................................... 13

“Noise” and its Effects Overview • 1

1 Overview

One of the most common causes of communica-

tion problems experienced by CPC site controllers is

excess electromagnetic interference (EMI), com-

monly referred to as electrical noise or just “noise.”

Because refrigeration and HVAC controls are typi-

cally installed in motor rooms and utility rooms, they

are often in close proximity to other electrical

devices that generate EMI, such as power lines or

motors.

Noise can be picked up by any length of wire.

Just as an antenna helps a radio receive AM and FM

radio signals, a long length of wire between a con-

troller and I/O board or sensor can also act as an

antenna for noise.

CPC site controllers such as the E2, as well as

the peripheral I/O boards and unit controllers to

which it communicates, go through rigorous testing

to ensure (1) that they are not overly susceptible to

noise, and (2) that the devices themselves do not gen-

erate excess noise. Regardless, every long wire used

in network, power, and signal wiring can poten-

tially be an antenna for EMI. Unless proper noise

abatement wiring practices are used, even one wiring

mistake could result in enough noise to impede or

disable an RS485, Echelon, or Ethernet network.

This document is meant to provide a list of

guidelines that should always be followed when wir-

ing RS485 (I/O networks, MODBUS), Echelon, and

Ethernet networks in an E2 control system.

1.1. “Noise” and its Effects

Noise, in the context of this document, refers to

EMI induced on a network wire or connector that

result in signals that hinder the controllers’ ability to

receive and send network messages. Just as loud

audio noise in a room makes it harder for people to

communicate with each other through speech, a

noisy network makes it hard for a control device to

read messages sent from other controllers.

You should suspect a noisy network if your E2

control system experiences any of the following

problems:

• Periodic outages of communication between the main

controller (E2) and its peripheral devices. This is most

often indicated by a large number of “Controller

Offline” alarms in the E2 Alarm Log, which usually

return to normal.

• Inability to commission devices during setup. During

commissioning, the E2 attempts to find a device and

read its commissioning information - on a noisy net-

work, the E2 may fail to find devices or require sev-

eral retries before finding them. Noise may also cause

commissioning to proceed very slowly.

• Intermittent Ethernet connections to E2 (ping works,

but UltraSite or InSite cannot make connection to the

E2).

• Communication outages that occur when changes are

made to network connections to the E2. Example: the

I/O network devices stop communicating when the

Ethernet cable is plugged into the E2.

• Reboots of the E2, in situations where excessive noise

is present.

1.2. Sources of Noise

The most common causes of noise in an E2 con-

troller installation are:

• Wiring that comes close to an electrical device that

generates lots of noise,

• Routing cable that runs parallel and/or in close prox-

imity to wires that carry high AC voltage and current,

• Network cable that does not meet specifications,

• Power wiring from the transformer secondary that is

the wrong wire gage,

• Improper network structure or termination resistance,

and

• Cable that is not grounded or that is grounded improp-

erly.

2 • E2 Controller Wiring Practices 026-1903 Rev 4 19-APR-2010

2 Avoiding Noise-Gen-

erating Devices

There are a number of electrical devices com-

monly used in supermarkets and buildings that gener-

ate noise.

• Motor starters, contactors, or other electrical equip-

ment that switches ON and OFF. Switching heavy

electrical loads ON and OFF will generate noise.

• Inverters for variable-speed motors. Inverters gener-

ate a constant amount of high levels of noise.

• Fluorescent light ballasts. Light ballasts also generate

constant noise.

• Arc welders (excessive intermittent noise).

The best way to eliminate network noise coming

from a noise-generating device is to keep all net-

worked devices and cable runs as far away from the

device as possible. Cable runs should be routed

around noise-generating devices, and the E2 (as well

as the devices the E2 is networked with) should be

physically located far away from noise-generating

devices.

The minimum distance devices and cabling

should be kept away from noise generators is 1 ft.

(0.3m) with 5 ft. (1.5 m) being the ideal minimum

distance. The minimum distance may be more or

less depending on the amount of noise generated by

the device - refer to the device’s user manual for

more information.

2.1. Control Techniques Vari-

able-Speed Drives

E2 controllers whose versions are 2.40F01 and

above feature the ability to communicate with certain

models of Control Techniques variable-speed drives

(VSDs) using a MODBUS network connection.

Control Techniques and CPC both require all

VSDs that will network with E2 controllers to be

installed with line filters to minimize noise. If install-

ing an E2 network into a site that already has

installed VSDs, verify the drives were installed with

line filters before networking them to an E2. Contact

your Control Techniques representative to obtain line

filters and assistance with installation.

In addition, CPC requires that all MODBUS net-

work connections to Control Techniques VSDs use a

CT Drive Interface (P/N 535-2725). This assembly,

which plugs into the RJ45 MODBUS jack on the

VSD, provides the noise filtering circuitry recom-

mended by Control Techniques, and it also provides

a screw terminal connector for easier daisy chaining

to the MODBUS network.

For further information on noise abatement when

using Control Techniques VSDs, consult the manu-

facturer’s instructions and follow all recommended

guidelines for installing the drive and reducing noise.

Furthermore, when using VSDs, it is highly recom-

mended you follow the EMI-resistant wiring guide-

lines outlined in Section 7.3., EMI-Resistant RS485

Network Grounding Practices.

Control Techniques Variable-Speed Drives Avoiding High Voltage Wiring • 3

3 AvoidingHighVoltage

Wiring

A common mistake made by wiring technicians

is to wire communication cabling in parallel with

120VAC, 240VAC, or 480VAC power wiring (some-

times together in the same conduit). High voltage

wiring radiates noise in all directions perpendicular

from the direction of the wire. When a communica-

tion wire is run parallel and in close proximity to a

high voltage wire, the electromagnetic field from the

high voltage wire will induce noise on the communi-

cation cable. The amount of noise induced depends

on the voltage and current of the wire, the distance

between the two wires, and the angle between the

two wire runs (with parallel being the highest induc-

tion).

To avoid noise induced from high-voltage wir-

ing:

1. If possible, wire serial, Echelon, and Ethernet wiring

away from high-voltage wire. Communication

cabling should be kept a minimum of 3 in. (7.6 cm)

apart at all points, with 12 in. (30 cm) being the

ideal minimum distance.

2. Do not wire communication wire and high-voltage

wire in the same conduit. Always separate the power

wiring in a separate grounded rigid steel conduit if the

two wires must be run close together and in parallel.

3. Avoid running even part of the communication wiring

in close parallel with high voltage wiring. A run of

parallel wire as short as a few inches could yield

enough noise to affect network communication. If the

wires must cross each other in close proximity, cross

them perpendicular to each other so the amount of

noise is minimized (see Figure 3-1).

Figure 3-1 - Examples of Good & Bad Cable Routing

4 • E2 Controller Wiring Practices 026-1903 Rev 4 19-APR-2010

4 Using The Correct Ca-

ble

4.1. RS485 Communication

Wiring

CPC specifies all RS485 I/O and MODBUS wir-

ing used by the E2 must be Belden 8641 (24AWG,

300V, CPC P/N 135-8641); Belden 8761 (22 AWG,

300V not stocked by CPC); or a 600V-shielded

22AWG equivalent stocked by CPC (P/N 135-0600).

These are two-connector shielded twisted pair cable

that support a maximum daisy chain cable distance of

4000 feet (1219 m) between the E2 and the end

device on the network.

Provided the cable can be routed away from

noise generators and running in parallel with high-

voltage wire, any of the three specified cables will

provide adequate shielding from external noise.

4.2. Analog Output Wiring

(Control Techniques

VSDs)

If using a MultiFlex analog output or 4AO board

to drive a Control Techniques VSD, you MUST use

shielded cable between the analog point and the VSD

drive speed input. Use the same two-connector

shielded cable specified for RS485 use: Belden 8641

(24AWG, 300V, CPC P/N 135-8641); Belden 8761

(22 AWG, 300V not stocked by CPC); or a 600V-

shielded 22AWG equivalent stocked by CPC (P/N

135-0600).

4.3. Echelon Network Wiring

CPC specifies one type of cable for Echelon Net-

work wiring: a Level 4, twisted pair, stranded,

shielded cable that meets all requirements for Eche-

lon LonWorks networks. This cable is available in

both plenum and non-plenum varieties from CPC

(see part numbers in Table 4-1). This cable is the

only cable type supported by CPC.

4.4. Ethernet Network Wiring

4.4.1. Shielding

Standard, unshielded CAT5/5e cable can be used

for wiring E2s to an Ethernet network as long as the

cable is not run near sources of electrical noise. Oth-

erwise, if the cable will be used in a noisy environ-

ment, shielded CAT5e cable (Belden 1533, plenum;

1533R for non-plenum) should be used. For this type

of cable, you should use shielded RJ45 connectors

meant for solid conductor wire (L-Com TDS8PC5

or equivalent). When connecting CAT5e cable to

shielded RJ45 connectors:

Cable Type CPC Part Number

1 pair, non-plenum 135-2300

1 pair, plenum 135-2301

Table 4-1 - Recommended Wiring

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