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EATON LV MCC COMMUNICATION OPTIONS

Table of Contents

EATON LV MCC COMMUNICATION OPTIONS ........................................................................................ 1

Overview .......................................................................................................................................... 3

Network Selection ........................................................................................................................... 4

PLC Vendors ................................................................................................................................. 4

DCS Vendors ................................................................................................................................ 5

Smart Devices in an MCC ................................................................................................................. 6

Electro Mechanical Devices ......................................................................................................... 6

Combination Starter Overload Choices ................................................................................... 6

Starter Overload Selection Charts ........................................................................................... 8

Communication Module Selection .................................................................................................. 9

Solid State Control ......................................................................................................................... 12

S811+ Soft Starts ....................................................................................................................... 12

SVX Variable Speed Drives ......................................................................................................... 13

Network Wiring in an MCC ............................................................................................................ 14

DeviceNet Network ................................................................................................................... 14

Modbus and Profibus Networks ................................................................................................ 15

Ethernet (Modbus TCP and EtherNet/IP) .................................................................................. 16

Ethernet Topology ..................................................................................................................... 17

Home Run (standard) ............................................................................................................ 17

Daisy Chain (nonstandard) .................................................................................................... 18

Reference Drawings ...................................................................................................................... 19

C440 OLR and DeviceNet ........................................................................................................... 20

C441 OLR and DeviceNet ........................................................................................................... 21

SVX and DeviceNet .................................................................................................................... 22

C440 and Ethernet ..................................................................................................................... 23

C441 and Ethernet ..................................................................................................................... 24

SVX And Ethernet ...................................................................................................................... 25

S811+ and Ethernet ................................................................................................................... 26

Eaton LV MCC Communication Options

Version 3.0 of 26 February 25, 20014

Overview The Eaton Freedom 2100 series MCC’s (Freedom and Freedom FlashGard) all have standard

configurations for common industrial networks which include Modbus TCP, EtherNet/IP,

DeviceNet, Profibus DP and Modbus RTU. All of Eaton’s smart MCC are tested prior to shipment

to ensure that the industrial communications is fully functional. As well, none of the Eaton

smart MCC’s utilize a gateway to bridge the motor control from a common network to the

industrial network. The Eaton MCC’s also have a scalable solution for motor protection

including control and monitoring across multiple motor control device platforms. The intent of

this document is to help select the correct type of motor protection and provide technical

information on the networks which Eaton uses in their MCC’s.

Short Discussion on Protocol

When talking control, or control and monitoring networks, it is important to understand the

different between the media (cable) and the protocol (language) and this is emphasized when

talking about our Ethernet networks. Today one will find that a specification calls for Ethernet

communication which defines the media and not the protocol. A simple way to look at the

difference between media and protocol is a home landline. The media one can see on the

telephone poles (or today probably fiber optic buried in the ground), however this doesn’t

describe the protocol going over the media. When both ends of the phone (wire) are talking

the same language (English for example) the two parties understand each other and are able to

communicate. If one end of the wire is speaking a language the other doesn’t understand

(English on one end and German on the other) then the two will not be able to communicate.

Taking this simple example to Ethernet explains why it is important to understand what the

controller (consumer) is talking so the MCC (producer) can have the correct devices installed to

communicate using the same protocol.

Eaton support Modbus TCP and EtherNet/IP over Ethernet as their protocols. Other protocols

one might hear are Ethercat and IEC61850 which at this time are not supported by Eaton motor

control.

Consumer Producer Media

English

EtherNet/IP

English

EtherNet/IP

Phone Line

Ethernet



Network Selection

PLC Vendors

When selecting a network it is important to look upstream at the control to determine the

correct network for the application. In many cases the control will be a PLC (Programmable

Logic Controller) and each vendor supports a primary network for their line or product family.

Generally speaking a PLC will be used in discrete control applications even though there has

been a trend to move into the process space as these processors become more powerful. To

simplify the selection, below is a short list of PLC’s by vendor and the primary networks

supported.

PLC Section Chart

PLC Vendor Leading Platform Primary Network

Siemens S7 Profibus DP

Schneider Electric Modicon Quantum Modbus TCP

Modicon Momentum Modbus TCP

Rockwell ControlLogix EtherNet/IP

DeviceNet

CompactLogix EtherNet/IP

DeviceNet



DCS Vendors

There are also other control systems which include SCADA (Supervisory Control and Data

Acquisition) and DCS (Distributed Control System) which are more process driven and less

discrete control and will be used in applications such as power plants, pulp and paper machines,

refining and many more continuous process applications. These vendors are consolidating and

support a wide range of control networks and a short list of the major DSC manufactures and

platforms is listed below. Most SCADA applications will communicate to any network as most of

these are PC based where a network card of choice can be added.

DCS Selection Chart

DCS Vendor Leading Platform Primary Network

Emerson Process Management Delta V Profibus DP

DeviceNet

Modbus TCP

EtherNet/IP

Ovation Profibus DP

DeviceNet

Honeywell Process Solutions Experion Profibus DP

Modbus TCP

DeviceNet through Rockwell

EtherNet/IP through Rockwell

Note: Rockwell relationships is

waning

Schneider Electric PlantStruxure Pillar Modbus TCP

EtherNet/IP

Profibus DP

Siemens Energy & Automation SPPA-T300 Modbus TCP

EtherNet/IP

Profibus DP

ABB 800xA Profibus DP

DeviceNet

Modbus TCP

Foxboro Invensys Profibus DP

DeviceNet



Smart Devices in an MCC There are many types of smart devices in an MCC, they range from across the line starters to

solid state control and include meters and breaker measurement. Generally speaking the motor

control devices will support all the communication protocols natively while the meters and

breaker monitoring will only provide Modbus TCP connectivity requiring a linking adapter to

bridge to the other networks.

Electro Mechanical Devices

Electro Mechanical devices refer to across the line combination starters where there is a

contactor which mechanically switches the power and then in combination an overload with

protects the load. For this paper the contactor is not important, however the overload relay

(OLR) is very important as options and capabilities change between the families.

Combination Starter Overload Choices

There are 4 selections of OLR in Bid Manager in the Starter Wiring tab. To choose the type of

overload, from the Starter / Wiring tab go to the bottom left and you will see Overload Type.

The selections for Overload Type are:

• Bi-metallic – C306 Overload

• Solid State Standard – C440 Self Powered Overload

• Solid State Standard with Ground Fault – C440 Self Powered Overload with integral

machine level ground fault

• Solid State Advanced with Ground Fault – C441 Motor Insight

• Solid State Advanced with HRG – C441 Motor Insight with low ground fault pick up settable

to less than 3A which is suitable for High Resistance Grounded system. For motors larger

than size 4, a D64RPB is used in conjunction with the C441 (already in the Bid Man logic) to

achieve sensing less than 3A. For Size 1 to 3 the C441 will detect to 3A residual Ground

Fault Current. For Sizes 4-6 must use a D64RPB to detect the ground fault since the C441

cant detect the 3 amp ground fault. The D64RPB is then wired into the communication

module so that the network can detect the ground fault.



OLR Communication Choices

All the OLR’s can be connected directly to an industrial network for control and monitoring with

the networks including:

DeviceNet / Modbus RTU / Profibus DP / EtherNet/IP / Modbus TCP

Pictures of the ORL’s in combination (except for the C441 Motor Insight)

Device Picture Competitor OLR’s

C441 Motor Insight

(link) C441 SSOL

• AB E3, E3+ and E300

• Siemens Simocode

• SQD TeSys T

• GE MM200/MM300

• Symcom 777

C440 Self Powered OLR

(link) C440 SSOL

• AB E1

• Siemens ESP2000

• SQD Motor Logic

C306 Bi Metallic OLR

• Many



Starter Overload Selection Charts

These charts are to be used to compare and contrast features of the different types of overloads

which are able to be installed in the Freedom MCC.

Protective Comparison

Protective Features C441 C440 C306

Thermal Overload X X X

Phase Loss/Imbalance X X X

Selectable Trip Class X X

Ground Fault X X

Current Unbalance X X

Voltage Unbalance X

Phase Reversal X

Stall/Jam X

Under/Over kW Trip X

Under/Over V Trip X

Under/Over I Trip X

Communications Comparison

Communications C441 C440 C306

DeviceNet X X *

Modbus X X *

Modbus TCP X X *

EtherNet/IP X X *

Profibus X X *

PowerXpert Software X X

* Connected to IO module for control and

trip monitoring only

Monitoring Comparison

Monitoring Features C441 C440 C306

Thermal Capacity X X

Phase Currents X X

Current Unbalance X X

Ground Fault Current X X

Voltage Unbalance X

Phase Voltages X

kW X

Power Factor X

Frequency X

Run Hours X

Motor Starts X

Time to Restart X

Control Comparison

Control Features C441 C440 C306

Hard Wire Control X X X

Local Reset X X X

Network Reset X X

Programmable Alarm

Contacts X

Network Control X X X



Communication Module Selection

Protocol Picture Part Number(s) Features

EtherNet/IP

Modbus TCP

C441R

C441T

C441U

C441V

4 AC or DC Inputs

2 B300 Relay Outs

Built in 2 port switch

DeviceNet

C441K

C441L

4 AC or DC Inputs

2 B300 Relay Outs

Profibus

C441S

C441Q

4 AC or DC Inputs

2 B300 Relay Outs

Modbus RTU Slave port for

secondary communication

Modbus RTU

C441M

C441N

C441P

4 AC or DC Inputs

2 B300 Relay Outs



Selection of the input voltage

By default, all inputs for starter configuration are 120V due to the control power being 120V.

The only time this is broken is if the customer specifically asks for 24V inputs or when used in

conjunction with feeder breakers. When monitoring a feeder, typically a CPT is not needed due

to the 24V inputs being self-powered by the IO card. When extra IO is needed with a S811+ or a

SVX then by default the 120V input version is selected.

For S811+ the control is usually 120V to the field and internal connections, therefore use the

120V input modules.

Kit Information

When combining the communication modules with the OLR or standalone they will generally

require accessory parts to make the connections and these are generally assembled into kits

which can be purchased. When a kit is available, it will be in the matrix for the specific OLR.

Description C441 Motor

Insight

C440 Feeder

(molded case)

S811+*

DeviceNet

DeviceNet module with

120V inputs C441K C440-DN-120

DeviceNet module with

24vdc inputs C441L C440-DN-24

C441L + C440-

COM-ADP

Modbus RTU

Modbus module without

IO C441M

Modbus module with 120V

inputs C441N C440-MOD-120

Modbus module with

24vdc inputs C441P C440-MOD-24

C441P + C440-

COM-ADP

Profibus DP

Profibus module with 120V

inputs C441S C440-DP-120

Profibus module with

24vdc inputs C441Q C440-DP-24

C441Q + C440-

COM-ADP

EtherNet/IP and Modbus TCP

Ethernet module with

120V inputs C441R

Ethernet module with

24vdc inputs C441T

Ethernet Standalone

module with 120V inputs C440-ET-120 C441U **

Ethernet Standalone

module with 24vdc inputs C440-ET-24 C441V C441V **

* S811+ Communicated via HMS Any Bus Linking Adapter to Profibus and DeviceNet

** Switch S2 configures the remote communication port for Modbus (ON) or QCPort (OFF) upon 24 Vdc

power up of the unit.



2 Speed with 1 or 2 Windings

• Each unit requires 2 OLR’s (Bid Man picks this automatically), one for the fast and one

for the slow speed.

• Each OLR requires a communication module (fast and slow) for control and monitoring.

• If needed a shorting contactor will be placed and then wired to the Fast IO card for

monitoring of the M contact.

Typical Monitoring and Control IO Points for Motor Control Devices

Typical inputs include

(1) Run contact from the contactor

(2) Run contact from reversing contactor

(3) Hand Feedback

(4) Auto Feedback

Typical outputs include

(1) Forward control when in auto

(2) Reverse control when in auto

MMX AFD

• The MMX AFD has provisions to communicate directly to Profibus DP using the following

option card XMX-NET-PD-A.

• The MMX AFD has provisions to communicate directly to DeviceNet using the following

option card XMX-NET-DN-A.

• If Modbus TCP or EtherNet/IP communications is required for the MMX upgrade to the

SVX AFD which has these option cards.



Solid State Control

S811+ Soft Starts

The S811+ soft start has native Modbus RTU onboard for a connection to the Ethernet modules

and to the HMS Any Bus linking adapters for DeviceNet and Profibus. The S811+ is the smallest

reduced voltage starter in the industry which includes a fully rated run bypass contactor rated

from 5 HP to 700 HP. All of the S811+ frames are mounted standard in the MCC with frames up

to 200mm able to be pluggable / removable units.

S811+ Monitoring Parameters

Thermal Capacity

Phase Currents

Power Pole Temperatures

Start Count

Fault Status

Motor Status

Power (kW)

Communications

DeviceNet (AB7001 Anybus Linking Adapter)

Modbus RTU (Native)

Modbus TCP (C441V)

EtherNet/IP (C441V)

Profibus (AB7000 Anybus Linking Adapter)

PowerXpert Software

Control Features

Hard Wire Control

Local Reset

Network Reset

Network Control



SVX Variable Speed Drives

The SVX VFD is comes with network interfaces to DeviceNet, Modbus, Modbus TCP, EtherNet/IP

and Profibus including many of the building automation networks. All of the SVX frames are

mounted standard in the MCC up though 500 HP including constant torque, variable torque and

18 pulse clean power. Eaton provides a 3% line reactor standard in each unit except for the FR9

(150 HP to 250 HP CT) frame where if the reactor is needed an additional section has to be

added for the reactor.

SVX Monitoring Parameters (short list)

Motor Current

Motor Torque

Motor Power

Motor RPM

Output Frequency

DC Bus Voltage

Fault Codes

Motor Status

Input Board Discrete Status

Communications

DeviceNet (OPTC7)

Modbus RTU (OPTC2)

Modbus TCP (OPTCK)

EtherNet/IP (OPTCQ)

Profibus (OPTC5)

PowerXpert Software (OPTC2)

Control Features

Hard Wire Control

Local Reset

Network Reset

Network Control



Network Wiring in an MCC

DeviceNet Network

DeviceNet is a trunk drop type network with the trunk (thick) being installed in the upper wire

way and then drops(thin) going down each vertical wire way where there is a DeviceNet tee and

then again dropping into the specific unit. DeviceNet allows for 64 devices to be connected to

one network. DeviceNet also uses a 600V rated cable with power and communication on one

cable and screwed IP20 type micro connectors at each junction.

Even though it isn’t required, many times a DeviceNet power supply is provided in the MCC to

power the DeviceNet network and devices (by default). Each of the communication devices

need to be powered from 24Vdc which is provided via the DeviceNet cable. At the time of

manufacture, the MCC is fully functional and is tested for communications prior to leaving the

factory floor.

DeviceNet requires terminating resistors on each physical end of the network; Eaton provides

these resistors for each Item. When connecting to the user controller, it is important to

understand this since many times one of the resistors will need to be removed and then placed

at the controller. When the MCC is shipped, at splits the trunk is unscrewed from the T and the

user must reattach this connection when bolting the MCC back together.

Below is an example of a network physical layout using DeviceNet showing the trunk and the

drops. This type of drawing is not provided as part of the standard drawing package as this is

only representative of a DeviceNet layout.



Modbus and Profibus Networks

Both Modbus and Profibus are daisy chain type of networks where one cable is daisy chained

from device to device. Connecting more than 30 devices together at a time is not possible

without the use of network repeater. Modbus uses a RS485 shielded twisted pair cable while

Profibus uses a specific Profibus cable, both these cables are 600V rated.

With both Modbus and Profibus, a network power supply is required to power the

communication devices since these networks don’t combine power and communications on the

same cable. This power supply is usually located in the center of the MCC and will then fed both

left and right to the communication modules in each unit. At the time of manufacture, the MCC

is fully functional and is tested for communications prior to leaving the factory floor.

Modbus and Profibus requires terminating resistors on each physical end of the network; Eaton

provides these resistors for each lineup. When connecting to the user controller, it is important

to understand this since many times one of the resistors will need to be removed and then

placed at the controller. When the MCC is shipped, each of the daisy chain connectors are

pulled back and rolled up to one section. The user must then unspool the cable / connectors, re-

rout them in the horizontal and vertical wire ways and connect the connectors back to the

communication module in the unit when reassembling the MCC.

Below is an example of a network physical layout using Profibus (Modbus looks the same). This

type of drawing is not provided as part of the standard drawing package as this is only

representative of a Profibus or Modbus RTU layout.



Ethernet (Modbus TCP and EtherNet/IP)

Ethernet networks by default use a home run topology where each device has a home run to a

switch which is local to a grouping of starters. There will be a switch located at each shipping

split so that Ethernet cables do t have to be pulled back from each unit when the MCC is

packaged for shipment. The user will be required to connect the jumper between the switches

to complete the communication between switches during install. The Ethernet cables are all

shielded and 600V rated. Switch configuration of 8, 16 and 24 port are available as are both

Level 1 unmanaged and Level 2 managed switches.

The switch is located in dedicated low voltage unit in the MCC so that a user can access that unit

without any voltages present with are greater than 24V. Some vendors place this switch in the

wire way and it is the view of Eaton that this is unsafe since to gain access one has to open a

space which has the possibility 600V present.

For Modbus TCP the default switch is the Hirschmann Spider II TX which is an 8 port unmanaged

switch. When more than 8 ports are needed in a shipping split then more switches are stacked

in that switch unit.

Form EtherNet/IP the default switch is the Hirschman RS20 which is a Level 2 switch with 8-24

ports and comes standard with the Professional software load. This switch has many features

and is EtherNet/IP conformance tested and integrates into the Logix platform of processors.

With Ethernet, a network power supply is required to power the communication devices since

these networks do not combine power and communications on the same cable. This power

supply is usually located in the center of the MCC and will then fed both left and right to the

communication modules in each unit. At the time of manufacture, the MCC is fully functional

and is tested for communications prior to leaving the factory floor.

When the MCC is shipped, only the 24V feed and the Ethernet jumper cables are rolled back to

one section. The user must then unspool the cable / connectors, re-rout them in the horizontal

wire ways connect in the switch unit when reassembling the MCC.



Ethernet Topology

There are two ways in which the Ethernet devices can be connected, they are either a home run

or a daisy chain. The standard configuration method is to home run each device back to a

switch and is also the most robust. With a home run a single device failure will not affect any of

the other connected devices.

Home Run (standard)

Below is an example of a home run configuration. In this configuration the devices will be

connected to a dedicated port on the switch and the switches will be daisy chained together to

form the network.

In each shipping split the switch or grouping of switches required for the devices in that split will

be connected so that switches daisy chained across the MCC. In this configuration the user will

connect their control system to one open port on any of the switches.

Split 1 Split 2 Split 3 Split 4 Split 5

Home Run Type Topology (Star)

To Devices To Devices To Devices To Devices To Devices



A non-standard configuration uses a master switch and then all the shipping split switches are

home run to that switch. The master switch is then the switch the customer connects to for

communications to the MCC. This method is used to eliminate a failure caused by a switch

losing power or breaking the chain.

Split 1 Split 2 Split 3 Split 4 Split 5

When a managed switch design is employed technologies such as spanning tree or ring

technologies can be used to create a robust self-healing network.

Daisy Chain (nonstandard)

An extremely rare network topology which can be used is the Daisy Chain. In this the devices

are all daisy chained to one another and then brought to a switch or a ring master with DLR

(Device Level Ring). In a daisy chain topology if one device breaks the chain communications will

stop after that device. With the addition of a ring master (DLR) the ring will heal, however only

once deice can be out a time in this configuration.

Master Switch

Ring Master

Switch

Optional Ethernet

for ring

Ring type topology



Reference Drawings



C440 OLR and DeviceNet



C441 OLR and DeviceNet



SVX and DeviceNet



C440 and Ethernet



C441 and Ethernet



SVX And Ethernet



S811+ and Ethernet

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