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Date Code 20141003 SEL Application Guide AG2014-30 Application Guide Volume VII AG2014-30 Using the SEL-3505 and SEL-3505-3 for Protocol Conversion and Monitoring Chris King and Samantha Sutherland INTRODUCTION During planning for industrial control system upgrades, engineers and project managers face many challenging design choices. Frequently, system users remove obsolete programmable logic controllers (PLCs) in favor of a more capable and modern programmable automation controller (PAC). However, the project budget may not support the replacement of transducers or loop controllers in the same facility. This can create an unintended integration obstacle if the legacy field devices use a communications protocol unsupported by the new PAC. Protocol converters can help to address this challenge by providing an economical means of integrating modern control devices and legacy field equipment. Properly implemented protocol converters have the ability to decrease equipment cost, reduce engineering time, and improve system flexibility. The SEL-3505 and SEL-3505-3 Real-Time Automation Controllers (RTACs) support advanced protocol conversion between multiple client and server protocols and have the ability to convert between different communications media. Additionally, the SEL-3505 and SEL-3505-3 provide secure communications, high-speed logic processing, flexible engineering access, real-time deterministic processing, and an embedded IEC 61131 logic engine. These features make the SEL-3505 and SEL-3505-3 excellent choices for control applications and system monitoring. When implementing protocol converters, engineers should consider both the details of data mapping and the transport mechanism for each physical connection. Two widely used media in industrial applications are serial and Ethernet. Serial links provide an economical, robust, and direct communications link between devices, which is useful for the configuration and management of field devices. Ethernet communications provide high-speed, interoperability, and large bandwidth capabilities that serve local-area network (LAN) devices. Many control systems use a combination of communications media in their configuration. To represent such systems and to show the communications media conversion capability, this application guide describes how to implement protocol conversion in the SEL-3505 and SEL-3505-3 between both serial and Ethernet communications links for control and monitoring applications. Note that references to the SEL-3505 in this application guide also apply to the SEL-3505-3. SYSTEM ARCHITECTURE The SEL-3505 can concentrate, convert, or communicate client protocol connections, whether serial or Ethernet, to a server protocol. A client device protocol or connection refers to data leaving an intelligent electronic device (IED) and entering a data concentrator, in this case the SEL-3505. A server device protocol or connection refers to data leaving the SEL-3505 and arriving at a PLC or human-machine interface (HMI). To use the SEL-3505 protocol converter capability, data will be mapped from the IEDs (clients) to the PLC (server). Mapping data points from a client device to a server device occurs in the Tag Processor, a program organizational

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Date Code 20141003 SEL Application Guide AG2014-30

Application Guide Volume VII AG2014-30

Using the SEL-3505 and SEL-3505-3 for Protocol Conversion and Monitoring

Chris King and Samantha Sutherland

INTRODUCTION During planning for industrial control system upgrades, engineers and project managers face many challenging design choices. Frequently, system users remove obsolete programmable logic controllers (PLCs) in favor of a more capable and modern programmable automation controller (PAC). However, the project budget may not support the replacement of transducers or loop controllers in the same facility. This can create an unintended integration obstacle if the legacy field devices use a communications protocol unsupported by the new PAC. Protocol converters can help to address this challenge by providing an economical means of integrating modern control devices and legacy field equipment. Properly implemented protocol converters have the ability to decrease equipment cost, reduce engineering time, and improve system flexibility.

The SEL-3505 and SEL-3505-3 Real-Time Automation Controllers (RTACs) support advanced protocol conversion between multiple client and server protocols and have the ability to convert between different communications media. Additionally, the SEL-3505 and SEL-3505-3 provide secure communications, high-speed logic processing, flexible engineering access, real-time deterministic processing, and an embedded IEC 61131 logic engine. These features make the SEL-3505 and SEL-3505-3 excellent choices for control applications and system monitoring.

When implementing protocol converters, engineers should consider both the details of data mapping and the transport mechanism for each physical connection. Two widely used media in industrial applications are serial and Ethernet. Serial links provide an economical, robust, and direct communications link between devices, which is useful for the configuration and management of field devices. Ethernet communications provide high-speed, interoperability, and large bandwidth capabilities that serve local-area network (LAN) devices. Many control systems use a combination of communications media in their configuration. To represent such systems and to show the communications media conversion capability, this application guide describes how to implement protocol conversion in the SEL-3505 and SEL-3505-3 between both serial and Ethernet communications links for control and monitoring applications.

Note that references to the SEL-3505 in this application guide also apply to the SEL-3505-3.

SYSTEM ARCHITECTURE The SEL-3505 can concentrate, convert, or communicate client protocol connections, whether serial or Ethernet, to a server protocol. A client device protocol or connection refers to data leaving an intelligent electronic device (IED) and entering a data concentrator, in this case the SEL-3505. A server device protocol or connection refers to data leaving the SEL-3505 and arriving at a PLC or human-machine interface (HMI). To use the SEL-3505 protocol converter capability, data will be mapped from the IEDs (clients) to the PLC (server). Mapping data points from a client device to a server device occurs in the Tag Processor, a program organizational

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unit (POU) configured in ACSELERATOR RTAC® SEL-5033 software that simplifies the mapping process.

Figure 1 illustrates the flexibility and simplicity of the Tag Processor. The SEL-3505 collects data from three SEL relays and one industrial controller in this application via four separate protocols: Modbus® RTU (Remote Terminal Unit), IEC 61850 GOOSE (Generic Object-Oriented Substation Event), SEL Protocol, and DNP3 Serial. It then converts the data to one protocol, Modbus TCP/IP (Transmission Control Protocol/Internet Protocol), and sends it to a PLC or HMI, as shown in Figure 1. The SEL-3505 continually updates and stores the most current status values from the client devices. Depending on the server protocol, status updates to the PLC can be polled periodically (solicited) or sent upon status changes (unsolicited).

HMI

InstrumentTransmitter

Modbus TCP

Modbus RTU

DNP3

IEC 61850GOOSE

SEL Protocol

SEL Relay

SEL

SEL-3505 SEL-2730MSEL

SEL Relay

SEL

SEL Relay

SEL

Figure 1 Communications and Connection Parameters

The SEL-3505 is capable of managing many signals within large industrial systems, but the project discussed in this application guide monitors just a few binary and analog points in order to provide an example of the configuration and commissioning process. The binary points, such as breaker status, are monitored by the relays communicating over SEL Fast Meter and IEC 61850 GOOSE. The relay communicating over DNP3 monitors an analog input representing the Phase A line current, while the Modbus RTU connection is configured to send an alarm notification to the PLC or HMI when the status of one of the instrument controller coils changes state. To complete this example project, the following software and hardware are needed:

• An SEL-3505.

• ACSELERATOR RTAC software (available for download at https://www.selinc.com/ SEL-5033/).

• ACSELERATOR Architect® SEL-5032 Software (only required for IEC 61850 MMS (Manufacturing Message Specification)/GOOSE protocol configuration and available for download at https://www.selinc.com/SEL-5032/).

• Three SEL-751A Feeder Protection Relays.

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• A third-party Modbus RTU device.

• Three SEL-C628 Ethernet crossover cables.

• Two SEL-C273A serial cables.

• A PLC, personal computer (PC), or any Modbus TCP client.

OVERVIEW OF PROJECT STEPS Before discussing the detailed project configuration, this section provides a general outline of the process performed in the two configuration software programs.

In Architect, you will create a new project to establish an IEC 61850 communications connection between the SEL-3505 and SEL-751A by performing the following steps.

Step 1. Insert a device into your project.

Step 2. Choose the protocol by which the device will communicate.

Step 3. Specify the connection type for the device as client or server.

A client connection is one in which the RTAC polls the connected device for data. A server connection is one in which the RTAC serves data to supervisory control and data acquisition (SCADA) or another remote client polling for data.

In ACSELERATOR RTAC, you will create a project to map tags (data) from IEDs (data sources) to upstream polling devices (data destinations) via the Tag Processor by performing the following steps.

Step 1. Insert a device into your project.

Step 2. Choose the protocol by which the device will communicate.

Step 3. Specify the connection type as a client or server.

Step 4. Upload the Architect project you created (Configured IED Description [CID] file).

Step 5. Create tags for the client and server devices.

Step 6. Use the Tag Processor to map each client device tag to the server device tag.

PROJECT CONFIGURATION

Architect Software Configuration You will begin this project in Architect to establish the IEC 61850 GOOSE configuration. GOOSE is a peer-to-peer protocol that broadcasts unsolicited messages to any subscribed device. After completing the Architect configuration, you will upload the GOOSE client configuration into the RTAC and the SEL-751A Relay.

Before beginning this section, ensure that the SEL-751A used for IEC 61850 GOOSE communications has the Enable IEC 61850 Protocol and the Enable IEC 61850 GSE settings both set to Y. Additionally, set the SEL-751A to the appropriate network settings. Refer to the SEL-751A Instruction Manual for more information about the settings changes.

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Step 1 Open Architect and right-click on New Project, select Add IED, and click SEL_751A, as shown in Figure 2. Alternatively, drag SEL_751A from the IED Palette and drop it in the New Project folder. Select the correct device and firmware version, as shown in Figure 3.

Figure 2 Add the SEL-751A in Architect

Figure 3 Firmware Version for the SEL-751A

To rename the project, right-click on New Project and select Rename Project.

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Step 2 Under Project Editor, select SEL_751A_1 and enter the IED Properties indicated in Figure 4. Note that configuring and downloading the CID file does not program any relay network settings. All network settings need to be configured in ACSELERATOR QuickSet® SEL-5030 Software.

Figure 4 SEL-751A Network Configuration

Step 3 Right-click on the New Project folder and select Add IED > SEL_RTAC, as shown in Figure 5.

Figure 5 Add SEL_RTAC in Architect

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Add the corresponding firmware version, as shown in Figure 6.

Figure 6 Firmware Version for the SEL-3505

Step 4 Under Project Editor, select SEL_RTAC_1 and enter the IED Properties as you did for the SEL-751A in Step 2. Note that configuring and downloading the CID file does not program any network settings for the RTAC. Configuration of the network settings occurs via the RTAC web interface. The settings needed for this project are the IP address, subnet mask, and the default gateway. Refer to the SEL-3505 Instruction Manual for information on how to log in to the RTAC web interface and set up the network configuration.

Step 5 With SEL_RTAC_1 still selected, navigate to the GOOSE Receive tab on the lower right of the screen, as shown in Figure 7.

Figure 7 Access GOOSE Receive Messages for the SEL-3505

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Step 6 Click the + icon next to SEL_751A_1.GooseDSet13 and continue to expand the + icons to show PRO > BK1XCBR1 > Pos > stVal, as shown in Figure 8.

GOOSE protocol operates in a publish-subscribe method. To receive a particular GOOSE message, the device must subscribe to it, and to send a GOOSE message, the device must be configured to publish it.

Navigate to the GOOSE Receive tab to see every published GOOSE message.

Note that the GOOSE message from the SEL-751A will send when the 52A Relay Word bit asserts. Relay Word bits represent the protection and control elements in an SEL relay. Every Relay Word bit is referenced by a label name that is a Boolean value. A logical 1 represents the element picked up or asserted, and logical 0 represents the element dropped out or deasserted. In this case, the 52A Relay Word bit monitors a circuit breaker. A logical 1 represents the circuit breaker as closed, whereas a logical 0 represents the circuit breaker as open. (For more information about the IEC 61850 logical nodes supported in the SEL-751A and the associated Relay Word bits, see Table F.15 in Appendix F of the SEL-751A Instruction Manual.)

Figure 8 Expand the SEL_751A_1 GOOSE Receive Message

Step 7 Click the Integer 1-200 tab and drag the SEL_751A_1.GooseDSet13. PRO. BK1XCBR1. Pos.stVal GOOSE message over to the Subscribed Data Item column next to INS0001.stVal, as shown in Figure 9. By doing this, the GOOSE Receive message is mapped to the Control Input.

All GOOSE points are aliased into tag names for reference within ACSELERATOR RTAC. Now, whenever the 52A Relay Word bit asserts, this GOOSE message will be sent to the SEL-3505, causing a change in the value of INS0001.stVal.

Figure 9 Set the Subscribed GOOSE Message to a Control Input

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Note that every relay contains its own default CID file with a data set for both transmitting and receiving GOOSE messages. If the SEL-751A default CID file is overwritten due to a previous setting change, proceed to Step 8. Otherwise, proceed to Step 9. Whether or not the relay contains a default CID file, Architect still needs to include the SEL-751A in order to configure the SEL-3505 for receiving and transmitting GOOSE messages.

Step 8 Right-click on SEL_751A_1 and select Send CID, as shown in Figure 10. A window like the one shown in Figure 11 will appear. Enter the correct information in the FTP Address, User Name, and Password fields, and click Next.

Figure 10 Send the CID File to the Relay

Figure 11 Network Settings for Sending the CID File to the Relay

If the connection to the relay is successful, click Next in the following screen to begin sending the CID file settings. If the connection to the relay is unsuccessful, check the network settings and reenter the username and password to make sure that they are correct.

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Step 9 Save your Architect project to an easily accessible location by pressing <Ctrl+S> or from the SEL icon by clicking Save. A window like the one shown in Figure 12 should appear. This file will be used once you create an ACSELERATOR RTAC project.

Figure 12 Name and Save the CID File

Creating an ACSELERATOR RTAC Project

Step 1 Open ACSELERATOR RTAC and select New SEL RTAC Project from the home screen. Select the appropriate RTAC firmware version, and select SEL-3505 under Project Category. Provide a name for the project, and then click Create.

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Step 2 You will now access the project created in Architect. From the Insert ribbon, select IEC 61850, and click Set IEC 61850 Configuration, as shown in Figure 13.

Figure 13 Set IEC 61850 Configuration

In the popup window shown in Figure 14, select the saved Architect project to upload the CID file to the SEL-3505. This completes the configuration for the SEL-751A IEC 61850 GOOSE client device.

Figure 14 Retrieve the IEC 61850 Configuration File

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Step 3 Next, you will configure the remaining client devices, server devices, tags, and alarms within ACSELERATOR RTAC. From the Insert ribbon, select SEL > 700 Series > 751A > DNP Protocol, as shown in Figure 15. Configure the Connection Type as Client – Ethernet, as shown in Figure 16, and click Insert.

Figure 15 Add an SEL-751A With DNP3

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Figure 16 Connection Type for DNP3

Step 4 Select SEL_751_1_DNP from the device tree, click the Settings tab, and enter the IP address of the relay in the Server IP Address field. Fill in the Client DNP Address, Server DNP Address, Client IP Port, and Server IP Port fields with your system information, as shown in Figure 17.

Figure 17 SEL-751A DNP3 Network Configurations

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Step 5 Navigate to the Analog Inputs tab and click the + icon at the bottom of the screen, as shown in Figure 18.

Figure 18 Enable Analog Input Tags for the SEL-751A DNP3 Server

In the popup window, enter 0 for the Starting Point Number and 1 for the Quantity, as shown in Figure 19. This should add the DNP3 Analog Input point AI_00000. This corresponds to Analog Input AI_00000 in the SEL-751A, which by default contains the value for the Phase A magnitude current IA_MAG, as shown in Appendix D: DNP3 Communications in the SEL-751A Instruction Manual.

Figure 19 Starting Point Number and Quantity of Analog Input Tags

Step 6 Add another SEL-751A by selecting Insert > SEL > 700 Series >751A > SEL Protocol, and selecting Client – Serial as the Connection Type.

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Step 7 Select SEL_751A_2_ SEL from the device connection tree and click the Settings tab. Change the serial communications settings shown in Figure 20 to match your configuration.

Figure 20 SEL-751A SEL Protocol Serial Communications Settings

Step 8 Enable the Fast Message for the 52A breaker status by going to the Meter tab and scrolling down to the tag SEL_751A_2_SEL.FM_INST_52A. Enable the status by changing the drop-down menu from False to True, as shown in Figure 21.

Note that the RTAC is aware of all of the Fast Messages that the relay sends. However, the RTAC needs to know which Fast Messages it should process and which ones it should ignore.

Figure 21 Enable a Fast Meter Tag

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Finally, ensure that the Fast Messages use the appropriate periodic messaging rate by clicking the Message Settings tab and verifying the poll period for the Meter message, as shown in Figure 22.

Figure 22 Meter Message Poll Period

Adding Non-SEL Devices in ACSELERATOR RTAC The RTAC is capable of polling third-party devices such as the Rosemount 3095 MultiVariable™ Transmitter with Modbus Protocol. This section illustrates how to set up the connection between the SEL-3505 and a third-party device using Modbus RTU. However, because each manufacturer uses a different Modbus register and coil map, check the manufacturer data sheet for the following:

• Which input coils and input registers receive analog data.

• Where the device logic engine stores data for the holding registers.

• Whether the outgoing and incoming data consist of bits, short integers, unsigned integers, signed integers, 32-bit floats, and so on.

• Whether the status coils store logic or output data, and the location of the status coils.

Step 1 Navigate to the Insert ribbon and click Other > Modbus Protocol, as shown in Figure 23.

Figure 23 Select Modbus Protocol for the Third-Party Device

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Name the device and specify the Connection Type as Client – Serial, as shown in Figure 24.

Figure 24 Connection Type for the Third-Party Device

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Step 2 Select the RTU _MODBUS device from the connection tree. Under the Coils tab, click the + icon and enter 1 for the Quantity in the popup window, as shown in Figure 25.

Figure 25 Enable Modbus Coils

Step 3 Click the Input Registers tab and click the + icon at the bottom of the screen. From the popup window, enter 1 for the Quantity and click Add.

The client connections are now complete. The following steps outline the server configuration.

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Step 4 To add another third-party device, click Insert > Other > Modbus Protocol. Change the device name, and select Server – Ethernet as the Connection Type, as shown in Figure 26. Click Insert.

Figure 26 Connection Type for the Engineering Workstation

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Step 5 Select the EngineeringWorkstation_MODBUS device from the connection tree and under the Coils tab, click the + icon. Enter 1 for the Quantity in the popup window, as shown in Figure 27.

Figure 27 Enable Modbus Coils

Step 6 Click the Input Registers tab and click the + icon at the bottom of the screen. In the popup window, enter 4 for the Quantity and click Add.

Step 7 Save all of the changes by pressing <Ctrl+S> or by clicking SEL > Save. All of the changes must be saved before entering the Tag Processor or the Tag Processor will not recognize the new tags created or enabled.

Using the Tag Processor for Protocol Conversion Now that all of the devices are entered into the ACSELERATOR RTAC project, the parameters to monitor and configure the protocol conversion and alarm notification can be defined using the Tag Processor.

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The Tag Processor is a custom user interface that uses a spreadsheet format to simplify data mapping between source and destination tags. This format simplifies your workflow by replacing the coding environment with the interface shown in Figure 28. The Source Expression specifies the protocols that need to be converted while the Destination Tag Name specifies where and under what protocol the data will be output. For this project, you will populate the Destination Tag Name column with each of the created Modbus TCP/IP input registers. Then you will place the tags created for the server devices in the Source Expression column. Mapping tags in this way establishes the data flow in the RTAC for protocol conversion.

Figure 28 Tag Processor Destination and Source Expressions

Configuration Within the Tag Processor

Step 1 Save your project and then enter the Tag Processor by clicking Tag Processor in the device connection tree window, as shown in Figure 29.

Figure 29 Enter the Tag Processor

Step 2 In the Destination Tag Name column, enter EngineeringWorkstation_Modbus.IREG_0000. stval. As you begin to type, you will notice that the autocomplete feature recognizes the created input registers for the engineering workstation. Select the first one (0000), and continue to sequentially populate the Destination Tag Name column with the remaining input registers.

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Step 3 In the Source Expression column, enter SEL_751_1_DNP.AI_0000.mag, which is the DNP3 analog input tag shown in Figure 30. Continue to populate the Source Expression column with the tags created for each of the client devices. Once all of the mapping is complete, the Tag Processor should look like the one shown in Figure 31.

Figure 30 Enter Data Into the Tag Processor

Figure 31 Completed Tag Processor Mapping

If an error occurs in the Tag Processor, try the following troubleshooting tips:

• Check that the changes made to the tags are saved. The Tag Processor will not be able to detect any changes unless they are saved.

• Check that the data type for the Source Expression and Destination Tag Name columns are compatible. Some data types easily convert to other data types, but if this is not the case, the Tag Processor will output errors.

Creating Alarms Within the Tag Processor Next, you will create alarms within the Tag Processor. Sending out alarms can be used for many different situations. For example, if Logging Enable is set to True in the Tag Processor for a Modbus coil, a change in the status of a Modbus coil will be logged.

To set alarms using the Tag Processor, perform the following steps.

Step 1 In the Tag Processor, under the Destination Tag Name column, enter EngineeringWorkstation_MODBUS.COIL_00000.status. Under the Source Expression column, enter RTU_MODBUS.COIL_00000.status. The Tag Processor should look like the one shown in Figure 32.

Figure 32 Enter Modbus Coil Status Values Into the Tag Processor

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Step 2 To enable an alarm for each time a change occurs, click the Options tab inside the Tag Processor and select Logging Layout, as shown in Figure 33.

Figure 33 Enable the Logging Layout

Step 3 Change the Logging Enable status for EngineeringWorkstation_MODBUS. COIL_00000. status to True.

Note that the Logging On Message and Logging Off Message fields are set to Asserted and Deasserted, respectively, as shown in Figure 34. Now the Modbus RTU coil can log an alarm for the status and conversion of the coil to Modbus TCP/IP. These alarms are viewable in the Reports section of the RTAC web interface under SOE (Sequence of Events), as shown in Figure 35 and Figure 36.

Figure 34 Logging Messages

Figure 35 Accessing SOE Reports

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Figure 36 Viewing SOE Reports

CONCLUSION Today, through the use of protocol converters, devices are able to communicate with one another and with control centers regardless of the protocol, connection types, distance from another device, or product type. Now, engineers and project managers do not need to spend extra time or money replacing legacy devices in their systems during control system upgrades. This application guide illustrates that, with the SEL-3505, data from multiple protocols and communications media can be received, converted, and sent back seamlessly. The SEL-3505 provides a robust solution for control and monitoring, and its compact design provides all of the necessary control for large control schemes and data management where space is limited.

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FACTORY ASSISTANCE We appreciate your interest in SEL products and services. If you have questions or comments, please contact us at:

Schweitzer Engineering Laboratories, Inc. 2350 NE Hopkins Court Pullman, WA 99163-5603 USA Telephone: +1.509.332.1890 Fax: +1.509.332.7990 www.selinc.com • [email protected]

© 2014 by Schweitzer Engineering Laboratories, Inc. All rights reserved.

All brand or product names appearing in this document are the trademark or registered trademark of their respective holders. No SEL trademarks may be used without written permission.

SEL products appearing in this document may be covered by U.S. and Foreign patents.

*AG2014-30*