February 2002 AirLink Communications, Inc.

Intro to CDPD for SCADA & Telemetry

1. Terms and Definitions

WHAT IS CDPD? Cellular Digital Packet Data (CDPD) is an open IP-based standard for transmission of data over cellular communications. It is an efficient, packet-switched digital wireless technology that sends data over dedicated cellular network channels. Charges are based upon the amount of data sent to and from the cell tower and there is a small monthly fee to maintain an active IP address. There is no charge to create the connection or to keep it open, only for the data that moves across the connection. CDPD carriers provide three alternatives for connecting a SCADA System to remote devices: 1. Using a Frame Relay connection into the CDPD Network 2. Using the public Internet 3. Using another CDPD Modem connected to the Host System;

Frame Relay

Internet

Other CDPD Networks

Local CDPD Network

SCADA Host

Remote Units

WHAT IS TELEMETRY? Telemetry is an automated communications process by which data is collected from instruments located at remote or inaccessible points and transmitted to receiving equipment for m easurement, monitoring, display, and recording. Transmission of the information may be over physical pairs of wires, telecommunication circuits, wireless radios or satellite. WHAT IS SCADA? SCADA (Supervisory Control And Data Acquisition) is an industria l measurement and control system consisting of a central host (or Master) and one or more remote stations controlled by standard and/or custom software. SCADA systems are similar to Distributed Control Systems (DCS), which are LAN based control systems routinely seen in factories, treatment plants etc. SCADA systems often cover larger geographic areas, and rely on a variety of communications systems. SCADA systems use a sophisticated database, provide graphing and reporting functions, offer an interface to operate equipment and have software initiated alarms to alert control engineers to specific conditions. Some examples of Telemetry and SCADA applications include Water Supply Systems, Waste Water Treatment Systems, Sewer and Drainage Runoff Systems, Natural Gas Transmission and Supply, Electrical Power Transmission and Distribution, Weather Monitoring, Pipeline Monitoring, Structural Integrity Monitors, and Transportation System Management.
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Intro to CDPD for SCADA & Telemetry

WHAT IS A PROTOCOL? A protocol is an agreed-upon format for tra nsmitting data between devices. Protocols used in SCADA or Telemetry networks determine the essential communication elements, such as: Network node address formats How the sending device will indicate that it has started or finished sending a message How the receiving device will indicate that it has received a message The data compression method used (if any) The type of error checking the devices will use

Protocols can be implemented in software and/or hardware. There are a variety of proprietary and open-standard protocols to choose from, each having their relative advantages and disadvantages. In the world of wireless communications (like CDPD), the protocols are usually based on serial communications. Examples of such protocols include the following:

BSAP (Bristol Babcock) DF1 (Allen Bradley) DNP

Fisher (ROC & FloBoss) Mercury (Mercury) Modbus (ASCII or RTU)

Opto-22 Sixnet SNP (GE Fanuc)

WHAT IS THE DIFFERENCE BETWEEN AN RTU, PLC AND DATA LOGGER? Short for Remote Terminal Unit , an RTU is a device installed at a remote location that collects data, codes it into a specified format and transmits that data back to a central station (or Master). RTUs also collect information and initiate processes directed by the master. RTUs are equipped with input channels for sensing or metering, output channels for control, indication or alarms, and a serial communications port. A PLC (progra mmable logic controller) is a small industrial computer originally designed to replace relay logic. It has inputs and outputs similar to an RTU, but also contains a program which will scan its inputs, and takes actions based on certain values. PLCs originally had no communications capabilities, but as they began to be used in situations where communications was necessary, modules for serial and IP communications started to emerge. A DATA LOGGER is a device designed for reliable, long-term, unattended monitoring in typically harsh environments. It uses minimal power to measure temperature, pressure, force or position using commonly available sensors, and stores the data into memory or on a PCMCIA Card for retrieval via a PC or handheld terminal. Data loggers are very easy to connect, and often use very simple protocols to communicate.

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Intro to CDPD for SCADA & Telemetry

2. Basic Telemetr y App lications

The most basic Telemetry applications involve acquiring data from a remote device that is designed to log a small number of analog or digital inputs for retrieval by a PC or handheld. These devices are typically very simple in nature, and dont have significant processing capabilities. Two means of communicating to these devices over CDPD are detailed here. UNSOLICITED REPORTING This applic ation involves a REMOTE device that is set up to send data to a HOST server on a continuing basis. This is often the case with remote devices that dont have a communications protocol, and can only stream data out of a serial interface. By setting the CDPD Modem with a pre-configured destination HOST, streaming data is sent without intervention or polling. This is easy to configure, but requires that the HOST have the ability to manage the incoming data. Data will look the same as it would if the HOST were connected via a local serial cable.

Remote Connection
Streaming data is sent from a remote CDPD modem direct to a Host CDPD Modem, which passes serial data to PC/Server.

#105000000x

#105000000x

CDPD Network

SOLICITED REPORTING (TERMINAL/TELNET AND SERIAL POLLING BASED C ONNECTIONS ) Many devices have an internal menu driven data collection mechanism accessible using terminal emulation programs such as HyperTerminal. Others have vendor provided software that communicates via a direct serial interface. For Terminal or Telnet applications, the Raven CDPD Modem is setup as a remote Telnet Server. Opening a Telnet session over an IP network directly to the CDPD modems IP will provide the Host with the same character interface seen over a direct serial link. Other serial applications will require a Host Raven or COM Redirector. These are covered in Section 3 under DIRECT SERIAL POLLING TO CDPD MODEMS .

Host Applicat ions

Terminal, Telnet, or Server Scripts open a terminal session directly to the CDPD Modem.

Remote Device
The device is connected serially to the CDPD Modem. The CDPD Modem will appear to be a PC on the RS232 port.

F-Relay
or

Internet

CDPD Network

RS-232

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Intro to CDPD for SCADA & Telemetry

3. Advanced SCADA & Telemetry Applications

Advanced applications involve a central facility communicating to remote devices using disparate communications, including circuit-switched (Dial-up) connections, leased-lines, and/or TCP/IP networks. This section will demonstrate how CDPD can fit into these unique environments. We will break this down into (2) main areas (with specific subsets): CIRCUIT-SWITCHED EMULATION: Dialing IP Addresses Using a Host CDPD Modem or COM Redirectors DIRECT-SERIAL POLLING : Using a Host CDPD Modem, SCADA IP Driver, COM Redirectors and Gateways C IRCUIT -SWITCHED EMULATION: DIALING USING A HOST CDPD MODEM Many SCADA networks dial out to RTUs that are connected to modems and telephone lines. CDPD can be used instead of telephone lines by placing an AirLink Raven modem at the host and one at each RTU. The AirLink Raven is configured so that remote devices can be called by the HOST software. By utilizing AT Dial Commands and the remote IP address, (ie: ATDT123.123.123.123), the HOST CDPD modem creates a pinned-up data connection. Standard asynchronous serial protocols are used just as if the system were dialing units connected to regular dial-up phone lines.

CDPD Dialing using a HOST Raven

SCADA system Dials remote devices using a Raven as a replacement for a landline modem. Modem provides RING and CONNECT messages as well as DCD, DSR, CTS & RTS

ATDT123.123.123.123

CDPD Network
123.123.123.123

C IRCUIT -SWITCHED EMULATION: Dialing USING A COM REDIRECTOR COM Redirectors enable applications that expect to communicate with a modem on a COM port to transport their data over TCP/IP networks instead. Redirectors can dial remote TCP/IP addresses as well as answer incoming connections. COM/IP is one example of a COM Redirector. During installation, COM/IP creates virtual COM ports along with virtual modems. These modems appear as Hayes-compatible modems to Windows software programs. Instead of dialing via phone lines, the virtual modems dial the CDPD IP addresses. Using a COM redirector allows you to continue using applications that require modems, while gaining the performance and cost benefits of an IP based network connection.

CDPD Dialing using a COM Redirector

SCADA system Dials remote devices through a virtual Com port and virtual modem.

F-Relay
or

Internet

CDPD Network

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Intro to CDPD for SCADA & Telemetry

DIRECT SERIAL POLLING TO CDPD MODEMS Some applications do not have dialing capabilities, but instead send a poll or message directly over a dedicated communications link. For example, when a Master Polling Station (PC) or Data Concentrator polls remotes connected to a multi-drop network, private radio network, or Telco leased lines, the Master sends messages (Modbus, BSAP, DF1, etc.) assuming that the device is listening on the network. Remotes look at each message to see whether they are the intended recipient and reply as needed. No dialing ever takes place. To enable these systems to work with CDPD, the SCADA protocol messages need to be converted to TCP/IP packets. This protocol conversion or IP encapsulation takes place at the Host and Remote ends, and is transparent to the Master and remote devices. Each message is wrapped in an IP packet, sent to a specific CDPD modem, unwrapped, and the original message is passed to the remote over an RS232 connection. This encapsulation can be done in one of (3) ways: Using a HOST Raven CDPD Modem Through a serial-to-IP driver supplied by the SCADA application vendor, or Using a third-party COM redirector application such as COM/IP.

All three methods have their respective benefits. We will examine each in detail. USING A HOST RAVEN CDPD MODEM Since SCADA messages are broadcast to groups of remotes, messages contain a remote unit ID. The remote whose unit ID matches the message will be the only one to respond. When using a Raven CDPD Modem at the Host, the remote unit ID is matched against a lookup-table of remote IP addresses maintained inside the Host Raven. (S hown at right ). Each message is then assembled into a UDP packet and sent to that IP Address. Remote modems are set to listen for these packets, unwrap them, and pass the data over the serial link to the remote device. Return messages are sent to the same Host IP.

Easy to maintain lookup-table holds up to 60 modem entries.

Screenshot of Wireless ACE modem configuration software

The HOST Raven

A Raven uses an internal Lookup Table to decide where to route messages. Software sends messages as if remotes were on a serial or radio network. IP x.x.x.1

RTU-1 RTU-2 RTU-3 RTU-4

= = = =

IP x.x.x.1 IP x.x.x.2 IP x.x.x.3 IP x.x.x.4

CDPD Network
IP x.x.x.2 The remote device receives only the SCADA messages meant for that ID.

Lookup-table looks at each message to find Unit ID.

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SCADA SYSTEM SERIAL-TO-IP E NCAPSULATION DRIVERS Serial-to-IP Encapsulation drivers are sometimes available from SCADA System vendors. They may include an I/O driver as part o f their application software. A good example is Bristol Babcocks Open BSI, which includes the ability to assign CDPD Modem IP addresses to remote unit profiles. While the unit may already have a BSAP Unit ID, (BSAP is Bristol Babcocks serial-based messaging protocol), it also has an accompanying IP Address. Another option is to acquire a driver or OPC server from a third-party developer, such as Software Toolbox. These third party tools perform exactly the same as SCADA I/O drivers, with all messages being sent to remote units via an IP based LAN connection to the CDPD network. CDPD modems attached to the remotes work the same as in the previous scenario.

SCADA System Driver

The SCADA system driver encapsulates the protocol into IP packets for transport over TCP/IP networks right inside the software. No external devices are used.

F-Relay
or

Internet

CDPD Network

SENDING SCADA PROTOCOL MESSAGES USING A COM REDIRECTOR AT THE HOST As previously described, COM Redirectors send serial data on TCP/IP networks. With COM/IP, we described the softwares ability to create virtual COM ports and modems. COM/IP can actually create up to 256 virtual COM ports on one single Windows ma chine! That means that if your total number of remote devices is 256 or less, you IP Address on right means that a can assign each remote device its own TCP Connection has been made separate COM port in your SCADA LEDs on left show activity on COM2 system. By configuring each COM port with its own unique destination CDPD modem, all messages are separated Screenshot of COM/IP showing serial activity & IP connection from each other and you actually have 256 dedicated packet-data circuits.

F-Relay
or

Internet

CDPD Network

NOTE: Much like the Host Raven, COM/IP will wrap each serial message into an IP packet. However, COM/IP does not support UDP, only TCP. While TCP is a robust protocol, it may be unnecessary given that most serial protocols are already very robust. TCP also has packet-size and session overhead you may want to avoid. The use of UDP vs. TCP for data transfer is something you should always consider when designing a solution.

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Gateways Gateways facilitate data acquisition by acting as the communications front-end, accepting multiple data streams to and from r emote devices. Gateways accept message packets from multiple serial interfaces and pass the data into a PAD (IP Packet-Assembler/Dis-assembler) for transport onto a TCP/IP network. Gateways are often sophisticated systems that can be tuned to interface with multiple protocols, manage large amounts of traffic, provide assistance with message timing issues, and keep detailed communication logs.

F-Relay
or

Internet

CDPD Network

THE AIRLINK TELEMETRY GATEWAY The AirLink Telemetry Gateway (ATG) provides a gateway and interface between legacy SCADA systems and Frame Relay or Internet connections to Wireless IP networks, such as CDPD. The AirLink Telemetry Gateway allows customers to seamlessly collect data from hundreds of remote devices through a single IP interface, reducing network communications complexities and enhancing SCADA system performance. ATG is a complete hardware and software solution that interfaces directly to the serial interface on the legacy SCADA system while also residing as a node on the IP based LAN. ATG can accept up to 18 RS232 connections from a single SCADA Master (or concentrator), and manage those connections while simultaneously providing the SCADA protocol conversion and data encapsulation for transport onto the IP network. Some of the features of ATG include: Intuitive User Interface Easy to Configure and Manage Support for any serial protocol Support for timing variances System Performance Analyzer Detailed Communications Log
AirLink Telemetry Gateway COM Port configuration screen

Protocol Configuration Screen (Showing Modbus RTU Config)

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4. Air Lin k Exp ertise and Customer Support

EXPERIENCE Since 1993, AirLink has been a recognized leader in the wireless data industry. Our founders participated in the development of CDPD, and have focused on developing data collection and control solutions for carriers, public utilities and transportation agencies. Our customer list is a whos-who of industry leaders, and theyre using our products for everything from monitoring oil wells in Oklahoma to tracking tour bus fleets in Hawaii. You can find our products attached to valves, pumps, switches, flow computers, data loggers, traffic counters, message signs or tracking ambulances and tow-trucks. Anywhere theres a need for instant wireless information. PROVEN SOLUTIONS From RTUs and PLCs to Data Loggers and SCADA software, if you use it, weve probably integrated with it. To give you an idea of what that means, we w ill let the logos speak for themselves. Here are a few you may recognize

PRE AND POST SALES ENGINE ERING SUPPORT AirLink always provides you with the exact information you need to integrate CDPD into your solution. Our Product Application Notes show you step-by-step how to set up your hardware, cabling, and CDPD modem configurations, with pictures and diagrams whenever possible. AirLinks personalized pre-sales engineering and post sales technical support is beyond compare. Our Field Engineers understand wireless communications, and know how to make things work. They come from all aspects of the automation, utility, and communication industries, and have walked in your shoes. So, if after reading this, you think youre ready to try CDPD, then were ready to help. Visit us on the web at www.airlink.com or call us at 510-226-4200. AirLink Communications We Make Wireless Data Work
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