MAC Systems

1
Welcome!
MAC Systems Wireless Seminar Brookfield, WI
March 25, 2003 John Callison, Regional Sales
Manager
2
Welcome!
MAC Systems Wireless Seminar Appleton, WI
March 26, 2003 John Callison, Regional Sales
Manager
3
Welcome!
MAC Systems Wireless Seminar Wausau, WI
March 27, 2003 John Callison, Regional Sales
Manager
4
Locus Profile

• Founded in 1979 in Madison, WI
• Privately-held
• 35 experienced team members
• Two product lines
• Industrial radios
• Loran-C timing and navigation receivers
• Customers include
• Motorola, USCG, Leica Geosystems, and AMCO
  Automated Systems

5
Locus - Experienced RF Solutions Provider

• 22 years of RF and communications product
  development
• Example RF products developed
• 900 MHz DSSS industrial radio modem
• 450 MHz remote meter reading system
• 418 MHz Active RFID tag / PCMCIA interface
• 900 MHZ DSSS miniature radio
• Wireless tire pressure monitoring system
• First differential GPS modulator/demodulator
• Loran-C timing navigation receiver

6
Locus Loran-C Receivers
7
Locus Industrial Radios

• Industrial grade wireless data connectivity to
  remote, difficult to reach, or mobile
  equipment/vehicles
• High quality, easy to use wireless products
  backed by knowledgeable and responsive support
  team

8
Locus Radio Product Line

• OS2400-485
• DIN rail-mountable
• RS-232 RS-485 multidrop
• Built-in addressed modbus DNP 3.0

OS2400-Ethernet Industrial grade wireless
Ethernet switch Simultaneously supports all 802.3
compliant protocols (TCP/IP, Ethernet/IP,
Modbus/TCP, etc.)
9
Locus Radio Features

• License free 2.4GHz (FHSS)
• Full duplex asynchronous data rates to 115kbps
  with low latency
• RS-232, RS-422, RS-485 data interface
• Automatic antenna diversity
• UL1604 class I, division 2, groups A, B, C, D
  hazardous location rating
• Superior noise immunity - advanced frequency
  hopping spread spectrum technology
• Integrated Modbus industrial communications
  protocol support
• Industrial quality -40C to 75C temp. range
• Point-to-multipoint with store forward
  repeaters
• Easy to use Windows-based setup diagnostic
  software with extensive online help

10
Regulatory
11
Benefits of 2.4 GHz
Less crowded than 900MHz Cordless
telephones Cellular Not susceptible to
paging/cell towers Similar range/propagation vs.
900MHz Greater bandwidth (3x) International
compliance License-free
12
(No Transcript)
13
General Description Spread Spectrum Technology
In 1980 the FCC authorized the unlicensed use of
Spread-Spectrum devices in the 915MHz, 2.45GHz
and 5.8GHz bands for industrial, scientific and
medical (ISM) bands FCC Part 15 rules specify
that devices can operate license free in the
900MHz and 2.4GHz band, 1 Watt maximum transmit
power
14
Spread Spectrum Background

• Developed by Hedi Lamar, gave to US prior to WWII
• A transmitted signal is spread over a wide
  frequency band
• The benefits of spreading the signal are
• signal is immune to unwanted noise/interference
• coding and decoding allow simultaneous
  transmission of multiple signals within the same
  frequency band
• provides inherent data encryption/security

15
Frequency Hopping vs. Direct Sequence
Direct Sequence (DSSS) In a high noise
environment, the reliability of the data is
dependent on the signal-to-noise ratio. There are
limits to the amount of noise in its bandwidth
that DSSS can handle. If there is to much noise
on a given frequency, communication will
fail. Frequency Hopping (FHSS) If a packet is not
sent successfully on a given frequency, it is
re-sent on a another frequency. By re-sending
data that was corrupted, the method becomes
inherently reliable.
16
Frequency Hopping vs. Direct Sequence Spread
Spectrum

• Direct Sequence (DSSS)
• Continuously spreads data over a wide portion of
  the frequency band
• In a high noise environment, data reliability is
  dependent on the signal-to-noise ratio

• There are limits to the strength of an
  interferer within the DSSS bandwidth and can be
  rejected
• If the interferer is too strong, all
  communication will be lost until the interferer
  is gone

17
Frequency Hopping vs. Direct Sequence Spread
Spectrum, cont...

• Frequency Hopping (FHSS)
• Breaks incoming data into smaller individual
  packets and transmits them on separate
  frequencies
• If a packet is not sent successfully on a given
  frequency, it is re-sent on a another frequency
• By re-sending data that was corrupted, the method
  becomes inherently reliable
• Receiver recompiles packets into original form
• No matter how strong the interferer is the FHSS
  system will continue to communicate

18
Spread Spectrum Frequencies

• 900 MHz vs. 2.4 GHz ISM bands
• 2.4GHz offers 3X bandwidth
• 902MHz - 928MHz 26 MHz Bandwidth
• 2.400GHz - 2.4835GHz 83.5 MHz Bandwidth
• Out-of-band interference is more common at 900MHz
  than at 2.4GHz
• The advanced paging and messaging services are
  licensed at 930 MHz w/ 3500 Watts transmit power.
  Transmitters are widely distributed
• Significant signal loss in the ISM 900MHz
  receiver due to saturation of the input receiver

19
Using Spread Spectrum in an Industrial Environment

• Antenna diversity to increase signal strength in
  noisy environments
• Repeater functionality to increase distance
• Immune to high interference environments

20
Antenna Diversity Increases Signal Strength

• Signals from multiple paths can cancel each
  other out - this is called fading
• Spread spectrum alone does not insure immunity to
  fading
• Moving the antenna 1/4? or automatic antenna
  diversity will correct the fading

21
Use Repeaters to Increase Distance Bypass
Obstructions

• Store/forward repeater to extend the network
  range
• Resolve line-of-sight issues i.e. hills,
  buildings, or other potential obstructions that
  restrict line-of sight
• Use to avoid in-building obstructions
• Illustration represents a network that would
  require repeaters

22
Repeater Illustration
Repeater Illustration
23
Wireless Solutions Where Cable is Difficult to
Install

• Revolving table - noise from slip ring contacts
  make communications difficult
• Remote sensors for solid, liquid and slurry
  storage vessels

24
Wireless Solutions for Mobile Applications

• Analog and discrete data communications to mobile
  carts or charging systems can be simplified
• Greater flexibility and faster change over time

• Wireless modems with hazardous location ratings
  simplify hardware
• Allows remote PLC programming or uploading of new
  set point parameters

25
Wireless Data Technology

• Licensed radio
• Narrow band UHF, VHF
• Cellular technology
• Cellular digital packet data (CDPD)
• 3G cellular
• Spread spectrum
• 802.11 wireless LAN
• Industrial wireless radios
• Bluetooth

26
Wireless Data Comparison -1
27
Data Rate vs. Distance

• Distance for outdoor line-of-sight with high gain
  antennas

28
Wireless CommunicationsData Rate vs. Coverage
Area
Industrial Wireless
29
Example Long-Range Network
) ) ) 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 ( ( (
) ) ) 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 ( ( (
) ) ) 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 ( ( (
) ) ) 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 ( ( (
) ) ) 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 ( ( (
) ) ) 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 ( ( (
12.5 Miles
OS2400 Remote Radio
OS2400 Master Radio
AMFAM
LOCUS
American Family Insurance
Locus Inc.
30
Benefits of Wireless

• Reduced installation costs
• Install quickly with no wires, conduit or
  drilling
• Real-time access to remote, difficult to reach,
  and / or mobile data
• Reduced operation costs
• Reduced personnel costs
• Eliminates leased line or wireless service fees
• Flexibility to easily reconfigure or scale
  networks

31
Traditional Cabling Costs

• Wire / Conduit Installation Cost
• 30 to 100 per foot to install (material
  labor)
• Repeaters add cost to wiring longer routing
  distances
• Cost to rewire as requirements change
• Time Value of Money Costs
• Lead time for cable / fiber
• Lead time for electrician installation
• Lost production while equipment is idle

32
Traditional Cabling Costs, cont...

• Cost of Wiring Problems
• Typically caused by wiring or connectors, not
  failed hubs, routers, or switches
• Machine down time reduced plant effectiveness
• Troubleshooting/repair costs
• Cost of Inflexibility
• When equipment is moved, typically requires
  rewiring
• Costly to test/implement improved production line
  layouts

33
Wireless Costs

• Wireless installation costs
• Industrial quality wireless radios are 1250
  per node
• Antennas cost from 0 to 350, depending on
  antenna gain
• Repeaters may be necessary if obstructions, but
  can be also used as remotes
• Installation costs minimal
• Site surveys may be useful for large
  installations where obstructions might limit
  performance or for a mobile application

34
Wireless vs. Wiring Installation Costs - Example
35
Wireless Cost Savings

• Wireless cost savings increase with distance and
  number of nodes

36
Wireless Benefits in Industrial Applications

• Temperature range
• Shock and vibration
• Hazardous locations
• Input voltage
• Installation, set-up and diagnostics
• Reliability
• Security

37
Security

• System security is an increasingly important
  issue for numerous safety, liability, and
  economic concerns
• Wireless devices (e.g. Bluetooth and 802.11b, or
  Wi-Fi radios) intended for consumer and office
  applications are specifically designed to meet
  open standards and are intended to be easily
  interfaced to other device adhering to that
  standard
• In contrast industrial radios are specifically
  designed to operate in a very secure manner

38
Security, cont...

• All 802.11b networks with 40/128 bit WEP
  encryption are vulnerable to attack from programs
  like AirSnort.
• Some nics no longer generate weak key
  combinations
• Passive attack - cannot detect
• AirSnort is a wireless LAN (WLAN) tool which
  recovers encryption keys
• http//airsnort.shmoo.com/
• " Weaknesses in the Key Scheduling Algorithm of
  RC4 " by Scott Fluhrer, Itsik Mantin and Adi
  Shamir
• http//www.securityfocus.com/cgi-bin/library.pl?ca
  t154offset10

39
Industrial Wireless Applications

• Industrial Automation
• Remote Lighting Systems
• Mobile stadium lights are currently controlled by
  a beacon light for positioning
• Radio modems could replace the beacon system
• Laser Cutting Machines
• There are several cutting heads mounted on a
  machine that are used for cutting sheets of metal
• Each head is fixed to a moving arm
• Remote PLC Controls
• Food Processing Industry

40
Reliable Operation in Weld Shop

• 25,000 sq ft metal building
• numerous metal racks/walls
• and overhead air handling
• each modem interfaced to PLC

• 4 welders work simultaneously
• and 6 arc welds present
• also plasma torch, metal shear,
• and break press

41
Distributed I/O Graphics Packaging

• One of the largest cereal box manufacturers in US
  with 23 plants
• Monitors pressure and temperature on an ink
  chiller system, which cools ink used in the
  printing presses. Ink temperature and flow are
  critical to quality printing

• Wireless solution more cost effective than
  installing 250 cable with a small
  number of I/O points

42
Distributed I/O Graphics Packaging, cont...

• Chillers are monitored with temperature and
  pressure sensors
• Sensor data are interfaced to a remote modbus RTU
• Remote RTU is 250 - 300 ft. from the master and
  interfaced to a radio located inside the
  enclosure shown on previous slide
• Master radio communicates using a modbus driver
  within a PC based HMI program (Wonderware)
• Five additional remote sites monitor similar
  processes and report back to same master radio

43
District Energy Hot Water, Steam, and/or Chilled
Water Monitoring
The importance of industrial temperature
ratings Minneapolis Energy Center
downtown Minneapolis installation of OS2400
radios cover 1 square mile area to
monitor building consumption of steam and
chilled water
44
Oil Natural Gas Production/Distribution
Sensors on wells, platforms, plants
pipelines Flow, pressure, temperature monitoring
control alarms
45
Water Wastewater Monitoring/Control
Wastewater lift station control Analog level
monitoring/on-off magnetic contactor Pump on/off
controls Alarm systems for high level
conditions Sewage treatment plant
monitoring Fresh water well pump house 4-20 mA AI
for pressure monitoring Discrete I/O for pump
on/off
46
Markets Applications, cont...
Tank Level Monitoring/ Control 4-20 mA output on
oil tanks Railroad Rural railroad signal
control - 2 Directional Yard switch
control Refineries / chemical plants Interest
from Eastman Chemical, PPG Industries, others for
4-20 via Modbus
47
Accessories

• Antennas
• Antenna cables
• Setup diagnostic software
• Mounting hardware
• Surge protectors
• Bi-directional amplifiers
• NEMA enclosures
• Solar panels

48
Two Basic Antenna Types

• Omni Directional
• This type of antenna receives and
• transmits radio waves in all directions. Power
  from this antenna is spread out in all
  directions.
• Directional
• This type of antenna transmits and receives
  radios waves in the direction it is aiming. Power
  from the back and sides of the antenna is
  concentrated to the front.

49
Antennas
Omni/Omni
Whip/Omni
Panel/Directional
(((((
Yagi/Directional
Parabolic Reflector/Directional
50
Path Studies

• Do I need a path study?
• Is your application indoors or outdoors?
• How far apart are the points at which you want to
  place radios?
• Do you have line-of-sight between these points?

51
Path Studies, cont...

• The customer provides
• The latitudinal and longitudinal coordinates of
  their sites, in degrees, minutes and seconds
• The known heights of any man-made objects
• The maximum tower height the customer is willing
  to consider on which to mount antennas